SERVICE MANUAL - Westerbeke manual/38673_5bcd_bcda_bcd… · SERVICE MANUAL 7 .6KW-60Hz/5. 7KW-50Hz...

SERVICE MANUAL 7 .6KW·60Hz/5. 7KW·50Hz BTD

and 5.0KW·60HZ/4.0KW·50Hz BCD 5.0KW·60HZ/4.0KW·50Hz BCDA 5.0KW·60HZ/4.0KW·50Hz BCDB

Single Phase DIESEL GENERATORS

PUBU CA n ON NO. t3N7J THIRD £DmONlSEPTL~ER I".

SERVICE MANUAL 7 .6KW-60Hz/5. 7KW-50Hz BTD

and 5.0KW-60Hz/4.0KW-50Hz BCD 5.0KW-60HZ/4.0KW-50Hz BCDA 5.0KW-60HZ/4.0KW-50Hz BCDB

Single Phase MARINE DIESEL GENERATORS

PUBLICA n ON NO. 038673 THlRD EDmONlS£PT£."lBER 19911

TABLE OF CONTENTS

latradaetiall .................... _ .. _ ..... _ ... __ ._._._. __ l

Engina TratiblesbDllting ............ _ ........................ _ ...... 3 Testing III O¥erlIaal . ____ .. ___ .... _. ____ . __ .... _ .. _ ..... 7

Engine Disassembly . ___ _ .... _ ....... _ ......................... 8

Cyliader Kead._ .••• ____ ___ .............................................. 1 0

YJJw: aad Villn Spring IIISJICctiDn _ ................... _ .... 1 I

V~1ft IlISbllatianIValwe Clearance ................... _ .... 12 liar Cast/GlIWemor •• __ ••••• _____ .... __ ••• _ ••••••....••.•. 1 J

• .ing &ear .. ____ .. ____ ..•. __ .... ____ _____________ ._ ................... 14

c.st\aft ................................................................... 14

Piston ad Connecting Rod ....... _ ....................... _ ... 15

ClaIksban ............... ... ... ................................ ........... 17

Cytillder BI,ck ._ ..... .. ... ... ................. .......... .... ....... .... 19

Gole,IO' Sysl:etn ...... ...... ..... ..... _ ............................... 20

~ne .tsseabI'_._ ................. _._._ ......................... 22

EDailstllanitold .. .... ................ .. ............ ................ 24

.................... _ ... .24

flel .. ;eetiOl:l PuIIIp ............•.. .. ___ •.•. .. ............. _ ... .25

flell.i1t PtIIIpJ1njmon Tillling ...•. _ ..... ..........•........ 26

fIeIl.jeetalS ........ .............. _ ............. _ ............. _ .•.... 27

Gin< PIIgS .............................. ............................ _ ... .29

c.4ait Cirulatillg Pomp ... _ ..... _ ..... _ •.......... ..... __ .30

IIa- Wmr PIIIIIp ................................................. _ . .3I

starter lIotor .............. ....... ................. .. ......... ....... ... .32

Dil P'ressii~ SwitclllOil PilISSII~ .•.... __ ._ .... _ .. 36

EIgioe ... djustllftlts ...... _ ...... . _ .... _._ ._ .... .. ............... 37

.ttterut ... Testillg ._ ................... _ ... ...............••....•.. .39

7.iIW DC Wiring Diagram (~ine) ........... ..........•. .. 41 un DC Wiring SchelUtie lengine) ......•............... 42

1

5.DlW DC Wiri llg Diagr.llill iengine) ...................... ..43 5.0lW DC Wiring Schematic lenginej ...................... oI.:

Generator Inlili"lUtioa ........ . ..... ... ... ......... ... 45 7.DKW BT &enemar Single Phase ... ~ .... _._._~

Troubleshooting ._ .....•........ _ ... . _ ................... .47

MO .... D<id Volt1ge Adjvstmenl •. ..• _ •••• _ •.• _ .•....••.. .48 Residoal Volt1ge Check ..................................... ..t9 Bridge ~ili~ .. ................................. .............. 50 EItiter/Rotor Field ............ ......................... ........ 51 Measuring Resistance ._ .................. _ ... _ ........... 52 Shore Power TrJIIsfer Switch .. __ ........ _ ....•.... .53 Specificatioos .. _......... ......... . ....... _._ .. _ .. .. >'

5.DlW BC Generatar Single Pbase _ .. _._ .. __ ...55

Trooblesbooting ....................... . .......... ... 56 DIal EIciter lIo ..... ad Voltage Adjilslillent ....... .51 Shore hwer Transfer Switc • ............................ 57 Single EIcit~ lIo·lud Yoltage Adju$Mleilt ... .58 talegral Contl1lll~ ........... ........... _ ......... _ .... _ .... 59 Testing tile Satlery Charging Circuit •.. _ ........•. 59 Sallast Rnistor ........ _ ..... ___ .. __ .~ .. .. 60

Testillg tile Exciter Windings ..... _ ......... _ . ........ 60 Field-Testing CapacitOlS_ ... _._. __ .. __ ........ 60

Testillg Component Resistance YaliltS ............. 62 SpecificatiollS __ .. .... _ ... .... _ •..... _ ..... _ ........ 63

Spft:ial Tools ... _._ ......... .... .......... ...... .. .... ........... ... 64

Semee Gata/Tolerances & Ulllits........ ... . .... . 65

Torque Specificatioll$ ......... __ .... _ ....... _ ...... _ .•........ 67

Slandanllbnlware Torques ........... _ ...... _ ....... _ ..... 68

Metric ClNI'ItTSions .................................................. 69 lodeI. ,_ ... _ .. _' .. .. _ .................. _ ....... _ ...... _ ................ 10

INTlIODUCTION PllOOUCT SORWW Product som.~ (ta;h d=. p>ru ....... ~

!:n><"""" ODd c:>l.1Iop) 1'""'- fmm """= OIher "'"" l'I.'ES1BUIEKE "'" noI ,..,lhin .... 'ESlEUIEKE-S ccnuaI_

WErr£RlIEXE aNNOT BE RESPONSIBU FOR THE CO,,"7ENTOF SUCH SOfTWARE. MII KES NO II~RRM71ES OR REPRESENTATIONS wrm RESPECT TH£RIT(), INCWOINGACCURACY. TIMEliNESS OR COMPu:T£NESS mERmF AND WIll INNO C',ENT BE UA./JU FOR A..vy 17Pt: OF DA.41AG£ OR INJURY INCURRED IN CONNECTION wrm OR ARISING OUT OF 111£ FUNNfSHING OR USE OF SUCH SOfTWARE. .... 'ES1UtSEKE CUWlm<rS >hoold 1II'" kc:qJ '" IIIInd tho ""'" !op:UI between prm!Jftl> of WESTERBEKE produa "'~wan: and tho ...... VOIdabIe e.u<u:""" of earlier y, 'ESTERBEKE manual., I'!'odu<t ..,ftv,= prG>'1Ikd ""til "',ESIERBEKE products. .. -b<1ha- from WESTERBEKE Of Dtb:r suppliers. mUS!. DOl. lDd ta/IIIOI be rcliod upon .~ as tho! Iknrulivc autbonty "" !he respeclI"< pro:Juct. II "'" only lIlWI &ood .sc"", bullS dIlpcnlI>< ilia! ~te ~ of WES't'ERBEKE Of !he >llPP!ier III qUC$bOll be coosulltd '" d<temune .... ac:ancr and aIImIlD<", of tho produa soli..."., bcllll con<ull«! by .. ~ 1tIllES, CAUTIONS AND WARNIMCS ..... IIW. ........... cUes you dwoullh tho disasocmbIy. lrupc<!Ian

and ossnnbIy ~ of your .",......~. allal WorrnaIJOn wtIl be: "'gIili,hIcd by NOTES. CAUTIONS, and WARNINGS. An upl3lWlOft f<>llows:

1IITE: /tII DfN"""" pTOC~"",."~,., .......

A CAII11OflI: ~ wItkI! It lIIIt stridIJ , ..... _ ~It irI tie ~ ., *WrH:tiG/S.t

,..- r !II i . Jt'!Ci"'IIf.

A WARNING; ~*'t!$, rftticb It _ '*"'*,,, frIl .... I'M IfISIIIt 1IJ ~ 1tIfIIt'f.,. " l ife.

OROEIUNG PARTS ~ lqllaa:mcnl potts .... needa1. a/woys prov.a. tho I"1IOnICIf _I """,bu. en""" ocna/ number. _ "'....,..,. .a'\aI ntanbcr as !:hey appear ()orI K1d poll .....,bef for each pan. 11O..:Icd (see tho ~ly fumishcd!>om !At). Also lnm1 upon WESTERBEKE p;ad.a~ parU beoust W'lU fit or cmmc portS .. tr.qu.n~y not made '" tho <am< Sp«;ificmolls .. on,~ oqwpm<:ru.

2

CUSTOMER IDENTIACATION CARD

i __ IWESTERBEKE

lho WESlERBEKE "",.>I number ~ an alphanumenc I10WIIba <hal. can ... ISI 1t1 &~l\InJ tht d>Ic of manufOCWt'l: of you< W£SiERBEKE ~"nclJe""""" lho Iir>I ~ ,..,;,. . .... !he dccadt! (A~ ]'NA. BaI970s. c..1~ [)..]9'IOo),!he oecO<>d dwxtcr r<pr=1S1bo >-= 1ft tho d<c3de.and!he fourth and fifth Dl,II"!lbef ~nI1 !he IIl<>IIIh of man..rocf1.lK.

5aUAL HUMBER LDCATION lho enJll>C and genenIor.enol number<; and modo] ''""''bet< .. ~ "" • deal on !he JeroeralO< """' .. ., lho enl"'" smoI number an """ be found ~ 'Ill<> tho .",.... block jU$I ~ d)e 1t1p:uon pump. lho senemor ...w IIIImbcr .. swnpcd tnl(l!he Jen=ll<l< housIn, Oft tho n......n.:. "" !he leh nd< of !he Jener.lWr

An idrnuiicauon pUle "" !he enX"" ma/ufald :oIso d,spL:ly;: tho """"" mo<\I:J and senaI numm.

The fono...n,...:tiono COI'IWn detailed ... f~ relaun& 10m. poper opo:t:&Uon dunaen<lic::s of tho "'¥'" cornpooelllS and ~ oflhc eng""'_ 1n<1uded "'" di....scmbly •• tUpeCtion and re&$.Kmbly IftSU\lC1Jons for tho ZUodanc:c: of S1.tiIIbIe tqlDfIp«I and sWJed ~ enl'''' ..,..".,. and rebuilclinl focihhes. The .......... ory p' .... dwc< <houId be III'Idauhn ""ly by """h focditoe:s

Add,1IOnOl detailed InfOfJn3UO<l ond .,.""fis:"""". "'" pnmdaI III od>or so.;lJOnS Df Lt." man..,.]. covenn! tht ,.,..,....,... a11<rDa1<1f. = 1I>0I01". ""I"'" lIdJU>LmenL>. coolin, pump>. =-

ENGINE TROUBLESHOOTING

pr<JlIIcm> m.w., 10 eacme 0CI'VIDt. lilt I' • U ~of .aT£: T1t< nil_'S ~lu",caI SU-..... IJ fI'OUCl<d Iro 11 ~ Ib<>t .. ubi .. " .. _ .... , Ai 1","· III " 'dCOi"" -,.", ~ "'_ wnw bfmh< no. pnlottJ: IIDintD,J IS IIIe5< II II ...... n. -. ~ be 01-"""" .. ~ _otd""tN_~

-.. ....... """ I ......... """ "".- lOW tIWIIJIIG S/'E£D

I Er9nt .>05aIWf""" , ReI*' ..... ..,ms_DI L~tDIJ', '--1 .",.. DnII}'. ,--4. BQoy_....,CU" .. , .. QurlIIfIfII'UIs ¥Ill __

S. DeIoo;M <Inf. S. __ CO "'*' _ I. IleItaM II\IJI ___

&. er.d< '**" 10< d<5o!r •• "' ..... ,.

DffK1l'lE IlETlOII rna 1. ,., ~ .. lUll PIIM9I 1. 8IeecI.1n:al1ud ~ L CIav;Ic 1uII __ L CluflIIr..pa __

3. \.oW .. P<mIn. 3. A<tuv:..., IftSSln

4. ~ $IlIlI'I. 4. Dun or.1dIu ~ S.~_~I· . .. ~Iult 5. ~ or ........... 1UI'CI I. ...... Il10 .. &. .... ~ IIIIrriI -- """'" I . \.oW"''' ...... l .. ---~ I . AQJnI_ damna! .. .-.-..... .-_tal . ..,-c. ___

L 1IIdItt ..... _ _ ...

I. ....., ... ~ .. ~-~ I . eo ... _1uII:I1IW\ItI;II ~ IIIIoIIglSIIeI I . IIfe/IU 0lSI& I. I'aIDa II1lI _

I. ~ JIISIDII "'" JIISIDII me I. ~,,-qlnCl~ .. ~ ... z.aom __

L ~gIow~ :a. fIDItt gIOor ~_ 1. c....;z 1NcI_ ..... , .. --.aPl'flOlM IIOS*O\ .. SI!II ..... SIiIIIn; ~

5. s-.oar ~ <lUI cr I'OSIlIlII """' ..... ~""'" "'" """"""" Stt HAIID SfNfmKi

IUEtTIOII smEM OIIT Of ~ 1. Mr:onEI qoc:\DI .... I . ~"""iIII:q 1. _ ..... l. ~. f'ICIIk:t..- ..... 1. l.o.,.,...,_. 3. a.ca: ...... roz:II _lII!r& III .......

IISUfftCUT fUEl 1. ,. ~ 1I1ueI1fSIn I.~_~w._ ,_ ..

L DRIIcr "*"'_ 3. t _1UII1ri. " ..... IISI.f'f'ClIillrWl AlII I 1. CIogge:I_ dUIIIt.. I. CIIan 01 '"IlIa. dtIr-.!


""""-' I PIIO ....... E tAUSl I VElUAUTION,1UMEOY

LOWOUTM~ """"', ... 1.t.-~ __ 1. Ioda-. 2. loooo \'-fIll 1. ~ 01 ~ II·DIIl

3. II'IaIn"ICI 0\IfICIIII'I tmn; 3. A4JIISI1tI!ICIJO" ~ 4. !.Doo enoN OIl __ , _ "",uoO'" (JIj

"""'" .. Ill. uuoGE

""-- 1 ~QII __ 1. IItIIIa 01 sealS

2. ar_our cas.o~ Z.~~ 3. Loose 0Uf ~ m.dWIQ _ l.~_

, I..I:IOSoe CQoII DIu; . :p , ... ~ 5. I..I:IOSoe aiI_ ttJme<:Or S. RtIlQfll6'l (If a ............ os • • Bnt:er> _~~ .. ~~ 7. l.Ilos.e _ awe. la:/III\g __ 1.1\etIgN1!I'I ~_ .. ""'-I . __ '....",I05'W".Cl_ mel 0iC'S- I . Coma me !I.:t __

2. !)splK4o!or_ COIo_'Il1IIII %. lIe$QItuo_'II rOC l . WOOl_mg l.~mg •. warn _ 01 tyIinII!r. • • ~ DISIOII MIC .-. tymler

01. lfII[l fAWIC I.~aern __ 1 . ~SII!m" L Worn ... If'III ... glide. • • I\e;IIIa • ...- on(I .... 11"*-

="'" "'" fJIGIIIE 100l TJlOUlIUS .,..,.,.. I . ,.., rr.atIiXIO 1. s.t K1«1C1aNG 2. Sr.D<y~ 2. See SMOKY EXMiJST 3. ~ ~~ _ 01 txaSSrVeI\'_ 3. IIe(IIIf Of I!IliD • • I'IIt;o"_ • • See LOWCOMl'RfSSlQN, HNW SjAlWI.G

5. _~"""1IftWIg 5. AajusI. I . _~_cttnra. •. --, iCiUtT IIITAI£ AlII

I . ~ nae 0IISI1UC*. 1. ""'- 0bSIruCta0II

""" """'" 1. SoDa 1ItIdt. 1. IIcpID,

2. warn IIOlZ!II 2. RepIQ.

11lPfl0P£ll FOO. RepIacI "'" p,-"",

"'" "'" I r.c 1Ull1uks.

"""'''''''''' "'""" " ""'"'" 1. Utzssro'f ~ all I. ConIClO,Otvtl

Z. £.ctzssr ... "., 01 001 1IIa!;I;IIIICIu$IIC~""" • . .Poor IIISI\:II QIIDCL .. -, . Sead_mg '.~OI_ • . ~~1;Iunra .. ~ .. ~

4


PII08lOl I PROIIAIlE CAUSE I V[RlACATIOIUU'IIlEOY

SMDIY EDIAI,IST /<Ht./ I WHITlSH OR PURPlISH (~I

(, Worn ....... stem PI .... guole .. ""'" e. If:M orono 01 ~_ ....... I. E:ccessM ail ~_ I. Correa

3 . IrqeaIon DnII>< IS 100 IU 3. MIIJSt. 4. _ CCII1Ife5SIOtl '0 See LOWClJMf'R£S$IQN: HAilD ST;.;m1ll'L

BI.AIXlSH OR IlW GRATISH

1. tngn bo<IV 1rCOJ*'. a.l'oo<~ I . Ser l!lll'C!lW'o'i£S$/ON /WID SiAiWMi ~. I~_ dutora. .. -

Z. _ ... '" (_ duI!r dl::Wel!l z. ca...n .. d!mtI. l.~lu.1. 3. ~ 'MIn _ lull.

......... """" ClWfl(SIW'T AND MIdtI BElII!NG OR NOISE. 1.BaIfy~~ 1. Re$ce /Ieam;I ono grnl ~

2. ~ -"I crrisNII. 2. GmcI tnMsIWt

3. Melted Deamo). 3. iItgIII:e ~ ;roO CI'Ied< ~ r,=

CONHECTtNG ROD oUID COHNEtIUlG AOO 8E.lR111G 1. Worn w.ot\lI.., f'OIl biiI trill OWWIQ 1. Re~oarng

2. Wom CtJ/lktIoII. 2_GmcI~

3. 8erI 1;01'_'11 fOCI. l . Cone<! toencI Of ~

PISTON. PISTON PIN. AND PISTON RlIIG I . W"",~. 1. RtDcn ty\indef!<> ~ _ r!;IIoa! pcs:on.

Z. W;,tn piston .... 2. ~ IIISIOIL 3. PistDn_ J. ~pt5lon""M<R~ •. Pis:o:l_.,., Mg ......, 0< ~ '0 RtpIxo PlSion on<! I"f1V'

VAlVE IIIICMAMlSM l_Wom~ 1. Re\IIQ.

Z. E" .. -~- ,.-J. Womllrilo~ 3. 1!.e\IIa. c. Wom bn Il'*I' IIAmg C. 1If!IIa:e.

IlllU6I1 DPERAfJOH IlUtTtOfI PIJMP SYSTEM I . u-........1njocbIn I . M.l5l ..,.ax>n<f '~IWU Z. Comd: ID mo/IundK:IFlng. 2. o;s .. ' .tllt.cnectnlcomc:~PIItnIJ

3. wan-....y-. , ""'"-'0 In'" .IB in!IdiOn oozzIe spqy. • . ~"'I'ICIJOI1 ~

GOVlI!II!NIi STSTEM

I . G!Mmor_~. I . CI'Iedc 0<>mn<>I .non _ t:IIrnCI aoer.oon z. Faigued _ SDm1- Z:~

5


-.. -- Y£RIACmDIC.1IDI:£Dl

"""' .. £1ClfI( IOIOCU WffiIDUlIllUOl s.oo: I. Wo\.-.ooN Ir\IUIlIeS I . ~cyInIe<. I . See rrvERH&lnNG. LOW~n>uT • . CItOOfIIIrIXISIS .. cyIncIet .0-1. foo..., qea,an wnng , ""'" 3.1oo • ....,pres5lR. ,. """'-4. ilI1I'*t lull. '.I\!oIIcI_ JIICCIII!I' I\IIi!I

lMOCllN6 WITH DW SMOlE 1. Poco- toI'iCWtsuon I . Sol! LOW~!PFi!SS1(1N;;WW r ........ "7/NG 1. II\tItWI ~ ~

I . INDm pIiIonger .. -•• ""- Is IICII n rntsn __ rD. •. ""'" C. ~~"s;mo,

L_ a. 'Nom 0IMry .... sell. .-

l.~_

I . I'oof l;Oj' iL a.. .. IfiI!Ia ~ ' .I'I;u",_"", .. ~ 01 I!PIIa 1If;df. .. _0, . ''"' L Rep.- 01 ~ IIII::If-~. NOI:lt ___ •. -..... """ 1. Full file! cIoQgtol. 1. CIu1 or fIIlIIQI .

OOWIST SlIUIID t . Full * IUCI:s oK. L ~ 1"OIt,PO 01 rwda:e ~ 3. w.r _ II kI!I 3. AoIIIoa! hIIII

"""' ... 1 • ..,.. sIidIio .... CIt sIiIi;ll!ff .... 011 1. ~ II!IIIIo:I Of o;!un.

1. IlIimIQIIC _.,.. ,-l. t.&td~ ,.-• . U. 0II1M1 Go JIOOr oil qwIify • . MIl ar <fIII'lDI! .. - S. Set KNDC1<1!Kl • • Yooong III'IJ __ ar IllII\IOM. • . 1IogIa.

7. ~ UI!O.""'" 7.1\eIIID.

lOW OIlI'RESSURf I . INDm k1mJ:s. t . 8Io;IIII1MINIuI1!;II&t ~ 2. ,.. ......... !n;8OR.. 2. o.tmIuI DIll _

l. ~001""" ,-•. 0iIs0II--. 01 ... cOL .. ~--

6

TESTING FOR OVERHAUL

HOW TO DETERMINE ENGINE 0VEfIHALI. I'£JUOO

caae 01 Low ~essioa ~. ft ..... " " 'lido :1ft "" ..... oIooId be O'vt 'led .. .s.. .. , .... by __ ~ sud! a>~"""De powoo' oo.op.o. deauoed compresoo<>CI pr=on.. and 1IIm.ltd fad ..d 011 ~ n.. Jo<oo=.:I ........ P""""f oucput. ..... .,.. gI dI<:$d alI'nes. os not neasM/'lly dut 10 IIOUbI< ..,."'" ..,.... , ... If. bu< II someumes c-.d by IIIJ«101'

"""zlr _ or "'~ pump ... ~. " " ""'" raIOIIIbIc 10 JUdI< br I doaus< 1ft ~ion ~. Tho dtausc .. ~ompt<$UOll poaIoIft IS aused by """'Y r~. It ... Iborden. ~ 10 delemunc I ........ or....- 010 die balls 0I.sa. prodIEed by penodjc .mp""''' ..s .... ,.. 0iI~!.&S oa I 'M'",,", bom os. ac.:.d _"'_..,en,. Jnurn.aI __ , v,'ho:tI cauoed

"'. *In t)iiacIm .. ptROII nllp. !be ~ syu..-.o .. -. I ,-...p..,....-u ... tpoIl I .... ' d C .... _ ... pIioa

3 be. d oiI ........... pc>. .. tt...o ..pac -nine S Noisy ..... Gpenliooa

Thotc S)U1pOIIIS .... "1'1"'31" togedxr. Sympoms (2J IIId "J ail r....tt Iho fin",~ ... fuel inJOCUDll. unpropcr .. ~ IIIIWIJ. aad __ of l low pup""", rmllu. They _~ abo by do:rcctive clcdrical .......... w:t> os d>t boacry . .......... <UIU:f ItId ,low plup. 1b=f_ II Ii cbnbk 10 .... ",. opimum ... """......m...IlImr- by !he Jo<o.aed ~ ~ c:aJI.ed by ---. cyliDXn """ ~~iIaeao<doil~~eoriq.. _" otua!d <1liiy under sufI'IcieM ......... ~ 1I'_ .... 1at:b ......... ' presaw. .... tr combus-_ 01 AId will lib: pbo:c: ac:a If _ pKts 01 .... ...... 1ft ; ... po ...... I)'.Tod<~lho:pcnodr;rl ... 1* --.... • " """""""" 10 <neasUn- cho. eapoc......... 1'0" praan ~. AI "'" same time. die ....,.... speed II ..-to Iho w:w::tWl of ""'4"' "'" P'CUIft II midi: Ih;IoIId be chocked ~ "'" """'4" s"" pn!SIlR ..... WIll> ""*' ...... Tho ettJinc rpm can lor ............s II d>o '""" cad lillie aWWft.

_Tt; To I4J ..., .... C""'I''US'"'' Ut dot ENGINE AOJ\JS'JMEhT uctiolt of dou "..".....j.

c ; = P'CUIft """"" 10 ma-s. .. bnIo '" I ...... ...... -.I poaa. ...... aad ~"" .....e ~ b<c.o brcUft IlL

~ •• CIOCr Me p>duaIly .... 1I>o pr!)Im$oI_ ........ .... ~ <II........ "CD pras>ft ru:bes _"'PI" ..... ...-_bc~ n.. ..... "'I"ftI ~ IIo'bca ad ......... 1iIp. 1!Io-'br ......... IIId ~ vaI_ ... II """' ....... '" ~ u.,- ~U1D'> ~ tr.r J9! pII. 28 t,ta.' at

"'''' 7

PrecamOllS lor IJisassembly and Rezssembl, What ~ ... <11Jl"<.. ~ecp '" .... 1Id Ibo 1oIloa-... 1""""' ,

Dtsassembly I. Belere ,10 .. Illy and .k3n,,, •. c:IrO'lully doo<;k for

d<fcas .. t.:tt """"'" bt lcund W. ~~ >nil

claol~''" 2. o.w. '"-..r. fuel and od btr,,", di ..... mbIy

1. Ou. or....tl dle ~nJ'~ UI¢tlOl'

-I. Do "'" ~ Of -.emblc pans Ib>i do IIQI reqwc d,',,' rubI~.

S. Pm""" disuKmbly III , Pf1lI'eI' O<dcr """" prOp<f ..... Keep de ."'d parU III onkr I\ppI)' oil wbao .,.,;os

arr. Tab: opeaal an 10 k«p dle ruel >ySIem '*" from ............. (1_ """- din.

ReM rtty I. CardnIIr dxck p$Uu.. pKbDp :wi oil oak ......

If cbrcb". IS .,. ope<:,1\oc!, Itf:pIAco willi _....,.

ifdof ........

2. 1k .... 1D ....... 1 ... '~o""'>IS'npcpor~and pooa-. (Pay ... tIIJDII 10 ~l polIS. ....., .. , "..,u and ope<:l6od dim:uons.) Who", uplUn, ""'l""" "'" sp=1ied, o:taen evenly 10 an Otd>nar)' IO<qU< AppI~' oeabftI ..t.= q>CCIhed.

1. ,oJru """""""" of ~y. rcchoct for ~ ~ I'repwc fot SWUft. d>o! eft""". and >dk Ibc ... """ sulIiaetIdy fot • \eSI Nil.

PRECAIJ1l1M1S • Ik arehII "'" 10 ...... bolls and __ '-1<1:1( ;lid S.A.£.

bolts .... IISCId on ......... '""I'K • ..,......

• DIKmI ~.~ clunnca ond ...... 'Cha ~ .... beiIIJ· - .t>kd IIIIt1c>r proper ordot and r.c.., III !toe coma di:'ecuOII III .. \loon 10 Ih< ... ,.... bIoct....a. as.. poADft$. poSIDII MP. bea1np and bunnJ .....

• I<ppIy ~I oil", _"" pans dcanftr; aucmbI~ 1 ........ \hie "'0""'1 pons. ..nen :I!lscmblcd on !be ttI,.""rowe Of lliclc ond .. IlOl "lbJOCl 10 10 ...... ' or ~~

• If Ihcn: ... """'.,_ talbell dun", di~. ref· e=<>: "'"'" tornedy fot _mbiy_

• Usc _ pkctL Ioc .... u.cn.. o-nnp. "'" • Tip.:.. !boo bolls :wi ...... on ImpDNnI p>N (1 .",,,," II>

SpeCofia! ~ ""'" ~ "'li.>blc Ionp wtme:h.. • Usc IiqI-' >e>Ianu ...no. fCCI'lIRd ... non. boll> >III! p..

k= Ror... &om """" lip: ocaIanu.

ASSEMBLY INFORMATION Ik IrW'tU<! _/ dr._ ~_"._ pobkms tNu CIUr 0CClU dwUt, ,-.~mM,.

i.....rliriell. Lubric:ation. Havdy 001 ,Mm, and """P""''''' Iftl paru.. b&lWly a" head boI" and """', fastctl<Y"- c1<Cpl ........ d>ao I"'fttImC 1Il10 Ihe ~ JoII<kcl. 1bcsc w' ,., .. _ bo: scaIed .. -nII P<:mw.c~ No.. 2 00 Ihe lugh-lrd> <qu:iv. -R ••• ncd Orimwioo. Mos! pskeIs. many bolt ,.znm. and 3lIl1>amosws .... 1ymm<tru::aL

Medlanical Oamace- Run r .. ",,..,,. Oc.o.'ft In Ipp"o.cd """"" ~ aod 10 Lhree 'ICJ'S' 11:2. 2Il. _ UI """",. ~ ~ tOrqI><-(O>.)""id bolt< and roc ..... ~.SIUft r ..... 1tneTS- 'Tho f...".... .,., ""'quod .. L~ "Th< blw-nxkef sIWI f~ >bouId be brvu,hI down In vay 0"'0.11 ~ mrn ... wtrll", from die ceo .... boll> QUI. GukeIs, e<p'C'.lIy had &W:rt<. 1'IIlglll Wo be damaged dunn& a=mbiy. ODd should b< positiOD<d ...,IIl gruI an:

............ Tht mi'''' ..... p" .... " II><: 1 6" w15 7Kw 8ID Gct!<"""" .>Iso .. u:sed '" power !be: ~ O"w/~_OK,.. BCD r<no;~ nu. ) <;ylll><ia dic!d cnl'no ""'" 1'- <llrouj:tI ,.".r:>l model de>lpalI",," W n .. _1IU3I1)' ""' ....... ~P'" , ... ~Iy .

n..: ttl, .... .....maul ~ ""'lIxIlng "'" IDIo:rance <UJdmis and 1Hru ...... !be ume for bo<h g<'tI<r.uors Ihmu¢loulllu. """,woI i ...... X~ brlog !he ""Ionder ben and 1""'" di""""tf~ Tho GE1'lERATOR SEcncv.-; CO¥tt'l boUt tho BID and BCD bao::k end •.

ENGINE DISASSEMBLY .......... 1>...-... """ grno.md .. ...,.. bailey ~ CODn<aion< and , .......... , and .. tum ~ lines..

i)r1monea !he AC ..... nl and unpIu. !he DC """"'I hame:<s. ~ II>< Ih<uhauI" """" MIlIe .. 2C1 mJCCl£d ~ Carefully suppon and d'Ion unbo/llhe genenlOr b><k eDd hun th: <"III1e. Sec SPECIAL TOOL'> - GEJIo"ERATOR.

8

W,,,, the FnenlOr ~ from "'" eng",. be,," !bc: foIlowm& <oq> by ...:p Pf<""'d= of ."y ... ~y

Dnan Iho ""II"" ail from the 001 wmp and nn Ihe a)O)I..m,

m.m the en,,"" and ~ .",IgnIC".

~rno'" II>< ~{en,,, .. ""1nnltwnns m "' c=uy Lahellhc \CmUJW oCXtJ>tC1>Otl< ' 0 C"",", proper re:>l1:I<h--

rIIr""'_"'-'_'" _._....,.

ENGINE DISASSEMBLY I. R.......,.t tho ... r' .... '"'~ c • ..-"""' .... _ If """"hie ... ~~ _

OtIC! of Q:h ""'" CCMCC_ ~ ",!he ~ be ... " mnooa1 For lTWIIO<unce . .... KEAT EXCHA. ... C£il

1. Rc_ .... ~' _ For SUIICI' ....,.... 1qI'U • ...,

ST,o.RTER MOTOR. 1. Remo-~ d'ot d~"lwl

... ~ chr "" ..... tac:km, pbIc 5. Uaboll elbows ~ bQd aMI mf>(tW: doc ~ bUl!llfoki

..... enutet)' Sec EXHAUSTMA."IR)U)

6. Rtmaoc Iho etI""" *M'IMOf ar>d ....... '"'31« pump 1. Itcmooot "'" """ne """",led r .. d fiIIct XIII fud I .... 10

.. JEC1X* pumJI (Nooo: "'" arnII,._ of aoh", .........

... "" bofIjO bob$ :II ""'I ri ..... ond 1A.,.a.o. I"""P-I &. ~!he IhcnnoIw housooJ _ do< ~

Lu>c 1<mpeIaNn:......su.. _ .. pII<c.

, . Remoo< "'" cooWK cllC'UlMnl'l"""P .t. 1Wn<M .... all' 1ftUIc. 1Iicft«t.

Nooo "" baoc ..." ... II rudy f« disasoenIbIy. cltat\la" >lid

"""'-L IWnooc "'" tqh pmstft- 'f\1IICICI' ... ~y .... 'bm ... 'I ..m IlljOClOr Woo &om die "JC'CUOI' _ .... ddnoay woI..., holder. '""" Ibe bokIet WICh a""""""" ICI~ ~ &orrt~. Aia_,1bo pi;><

membIy, pIu, "'" ~ hoIdots -' dttr-y .-.ho: IIioIdm 10 Ift'-__ tJI ~

1. Dos:: ., Ib!: IfDw phi, 1eaIwn. J. I..oooaI chr (mil ..--. ~ ..... bdt.:l d.smoIa.lhe

lid!.. ..... pulley and bnle:keI. , .... _ btucIItI' bow..

CYlIIJER!£AD REMOVAL 5. Itm!ooe .. rocker _ .

" ~!be rod<a sIW\ ~ 1. l.- .... cylinder hc.Iod II'IOUaIIIIJ boIcs .... ylftd ~ III Iho IlUll'lCntaI order • .u...r-d ond mntI'f<

... cyl_ hc.Iod auanbly (mcluduoJ "'" uhal$lmano-

"'"

• I. Wi .... cyIirIder bead oil' "'" "" ..... ,. Re........ "'" cylild<r bud p.kct (i. !lor cy\ttId<t

be..t _ "'" qlmdoa bIo:;k...,{.,." fnIm ... hoc" .... p.m 1m bca:. !eIIIoD'>td.

10. R<III<rY< "'" iOj<CUIr ~ xod """ plup from 1Iv: _ ..... 11 . Re!nooe "'" w..... manif<>ld from the cy\dIda' bead L!. R.:mcM: tho ,-.I~ mam.on. vol ... q:>n!lIS Mel \101~

&om Ill< qli:l<:l<f t.::.l """'"" ranowml e.xh ,~ ... maIIIOr. cIe;lr= Ihe rti.OIner apolW !he n/,,, ....... and """""" lilt I1:WIXf loci<. Ideno.fy ...m "Ill ... by puwn, a mart. rOdjt""'I "'" IIWnbct "'!he t)'hnckr from .. "",,, "'" val .. is ~

13. Remooe .... ,-ave stem seals.

CYLINDER HEAD Cylinder Head Inspection Cbn \hi: cylmdet lflii !hi: cyliador tm::k ""'"""" from ""luch Ihe ~ Iw bcaI """"'""" c...fully check the C}'I,r>det hal (Of Cr.><1:< or .. y other d>m>ge :u; shcN.'ft below Usc • i<r.>Igt«dge >nd • ~ pIfC '" thook the ..naa: far dlS/OrtIOCI ond .. -..pace. Check III< v:II,,, rw<k> ond vIDe <;<mUr;t "","..,..,

~ __ ...... _ .... 11.1_1

YalYe Guide Replacement If H·al~. ",>de IS found ddccu,· ... rqlI"'" Il

1. Rem,,,,, Ihe vol .. (II>d< by JnSS"II a <IS upper end >nd pull " ow '" Ihe nj ... seal <ode •

.!. 1JUbl1 Ihe 14mm

10

Valve Seal Repair If. ~\'e ""'" IS found defc<.1J¥e. r<f," " Of 113"" • rnxh,oc sIIop mw.J1 • __ """'----_ 1.81!1i1(O.S-) ~ 1·_11.5"1

NOT£; Mw-It d.~dan6'~ nltka,... W ..,1\ ... 6'olJ. nms' br III nonnaJ «JNltnDrL R'v<tjac. W "<>1 .... 'nzI '" do¢ ,, <'_ laCfS rk ....d.pa ... "" of ~ ."Ol,'. fau.

ktrtailillg T1Ie Cyli .... Mead l...uI laloon of <h< cylinder he:Id IS ,n tho ",.tt<c ord« '" lernoval P:!.y >lit"""" to the fol"""m,. I. Rene ... · the cyh l><h h<.:id l..tei. "''' >JIP>aUO<ke\ '" >;>pI>03bIe 8< """,rul no< 10 conf .... " .. ',lit. ¢ ... fOf .no.I.,,, cnf,n<

"""' . .!. Til hle" the cylinder I><.>.l bolts ,n ,roo n\IfJ\cnQJ nrdCf

<how" png ,"""j'h IN! ,!fdocr '''''' (It IhI= Umc>. Tip" ,,;o.:h boll " Ioulc aI. Urn< untl] >l1:J/fc (,~ ....... ....t 10 the ' p<\:, 1>eI! '''''I"'<

$ n

• o.

VALVE AND VALVE SPRING INSPECTION VAlVE REMOVAl I. Dt..n ....... 1h< "~h"""f he..J """mbl}

::. [)qn..1ht • ..:1 • ., n:LlIna-110 <"."pm;> II>< .-:>I,-~ opruIi )

>lid ""n",.., .he m:I.In." lock.

"""'" "'m J. R<mo"~ II>< v:oI ••.

~. Inspea >II tho< """'pone .... >lid n:p&Il" 0< replxc ""~ dcf",,~ P'l/'IS.

$", a... _ r _ T

Vo/wr Sp"", Sq ... ,...,... Ched<.. ~k \he oquareness cL Iht n/", 'P'I"~ >nd. If " " """" ~ !he "nuL rqKacc Iht .....

11

v ... .., Sprinc Filii", 1'T=w", a...t... o...:k lilt ,-,joe "J!nlll iiltJnl preuun: .. ,," ~ .-.I ... iJlnnl -.. :IIOd. 'f Ih< ~ " leu Ibaft Iht hnu .. I!'J'U<c II>< opnng __ (!NoII_ -... 'l.Ot:i...., .JSIioCi .ioIq.15.5_1 I.loU ·15'10

IIOTI: M.~ tk Ji:<uoG p~~ oftt, ctJmpnlSml til, ,.,rutg ",',rr:l """'L

v ...... Sp .... , F_ t..:agtb Chrd.:. Mca. ..... rhe me length of !be _..:I • .., """III atId .f Iht 1m: Icnzm II I<:S$ INn Iht lIfl'ut.

""'" "

Valte Inspection

, ......... ,aI -... 1.w;.!tlU _l lAo! 1J iI (11.3 _ 1

V:o.I·c Slem ",oar '''' I cbon. rrlbe .71 • .., >!em I> b<m <lr "" dwncttt IS leu Ih:m Iht SWIC!>rd. tq>I;r< II>< ,-,J" ---.... - 1.1_II.mill

U_ IIJI'101

I. Iflhe • ..:1", fxc IS found worn """'n. resurfxt ~ ,'"lI! ~ • ..:1"0 ",fo>ocf If Iht """S,a of me resunx«I .'l!"" e.KeeCh Iht OC''''',;. hl7\ll.. ~ the ."he.

::. If ..... valve SlCm end ..... boen ,ndrn ... -d ~ ... ,," l\;JI!en" .. "'" :ttl Dol "0fIC.

VALVE INSTALlATION I VALVE CLEARANCE Installatioa 11IlUI1,1Ie val"" >lid ...... . < ;pnnp.. Ikfer 10 Ihc ,1l1,OStr.>t><>n> 0I>d c:>lloon ohown bel"",'

110ft: &! NJ.Rfol_ /0 ~~ rio< ,pnn1 and "" .. JnJ b. uuu". Iv ra"'p"u'mg ,,.,, SP""I -..11<" ,,,,,,,,11"'1 IW va!>..: 'P""I MOIl"" II .. Cyhndct Had AsKmbly >nd .oiJIISI !he ,""h. ,-

- .. --rrtJl .... '»lIIr.....,._ ... --

TorqIIing The Cylinder Head Bolts .:nt: Cyimtkr hnd bola mJm M rrrit;hu"'d «forr tMijllJl' u., 1M ...m. ck""""'",-

T,p..!he cy~nde. bad bolts oc:cordift,lO Ihe!he oequer>a: .-... M2ke SIft the C1IJ,ne IS cold o.1Ien IIw .. dane.. !kf<:R applY"" IhI: '!'C<JI'Icd <orqu< '" lhI: boI<.loo<en" lf~ 10 112 of . wm and Iheto JPPIy lhI: IOrqI>e. FoIk>w !Ius procc, dun: a:ccm...1 '" tho numbered oequcnct ........ n '" tho ,11 ... --_t1,: ... 1l

_ 11_ .... '.·I2 .. /U·U ..... I· _ fe, 5.1. J, I . t. 10. ,1

_ 1'_'-' 5oj -I'''{1.li -I.li\;f1l) .

. ' ... ---_Il_~ n · lli"(1.li·Ua,.-~

12

011

o.

CTUllEllIIElD IClJ ~ SSIUE.:I

MOlt: Tlte Rocw ""l<'!bI\-,btu "",." SJwft aN! Sl,,,,, QIl' _ '" 1M ""I,n< ./r"" iii. n/",k, _ 1>010 U~ 1l'''1!rJ· .1Ud '" tIu. p",.-cdJur.

"

I.Ill1i1 ~~) .. -I. SCI!ht cylmder to be odJUS<Cd 10 "'" TO!' Dead C • .-.

(T_O.C.)oI .... Ihc~W'OIo:c VaI", c~

0.010 ID (Q.25 rnm).oId for boch.DtaU _ • .tW.SI ,.= 2. Tho Top DeaiCemerof Ihe compressi.on SImI;e =0 be

(lin,,,,,, by ali""". II>< T-D_C!>Im (lIOICb) ",,!he ~ purley...,\h Ill< mm. "" Ihc so:ar c:H< .

l. FIf5I. ali", Ihe TO C. mart for tht No. I cylinder. COftfum dial tht .111..,. dn1lCll rna", """",, _'II ... n.n .... cnnk<boft .. <IIfDOd Xl" '" !he ........w drrcroon of ,.,...;0., aDd .n lito: ='<~ di=:uon.

4. .... 'hen sctWI&!he TD.C. For !he ,,1 aad w2 9~!Idcn.. per. f<llm as follows. From Ihc TD.C. fer "'" _I cyltOder. rum Ihc cnnbIW. 240" c~ It> $< . J cyhndt, T D.C. MIMer. WIn II>< crukshah 2-'0" d ""l<w ... 10 in

II>< _2 cy~ndt. 1O T.D.C.

GEAR CASE I GOVERNOR IilAR CASE ASSEMBlY I . R.:tnuvc .... tk1 .. bell "'" Iho """I.;iun puI~ Z. Rnnm~!he >I1CmOi1Of J. !kmo." tho: ,._, pump

W'l8I~

=-

4,. Rtrno..-. th< ",,-.rod-...

~-S. ik,,,. c=ful _ III .., .... """'" falllf110 III< ~.

"'......., tho:: ",,·rtd:or.d Ibc .... ·taI ~g 6. Rcmo •• me ID>UnOt <au coYer

7. Remov<: Iho r<->< ""'" at<mbly I. lflSp<rt tho disAscmbIed pM$ ~ pa:'IS ""'"'

bot yond ~:or.d""'1CI! 1_

--. --. ..... ---• Froat Oil Seal Replacemnt R._:and ~_Ihe ffOlll 011 JUI AppIY'!Iun COOl of ."""" 011 to the Clmlmr.....,., :or.d Iho l ip of the oe .. d belen pr"tU-~U'.' ~ w Ihe I"l" ta5C co~.

lOcm:rnor Shan Olsassembly/lllSpeCtiOll

NOTE: F"N.dds,..,..m 1IIje.-.s_ trJ~, lO W COl £R\OIl SYSTE.1f .«'1Oft. I. T:Wn1 e>re 10 .... ,",~h .... fur ''''<. """0'" Ih<

upIIIWOII p/U.

1. R ........ " Ih< pIl(/'Cd p'~.

, ""'~' ..... ~

_ ... n ---

-~-1IST.w. TIlE "" ..... SIWl

5. Cbo:::k "'" ro.cmor p>nlI ror ..-. dam>", . .and bup" If ""Y p3I'U ..., <kfecu,·c. ~ Of 1qIb. .... Ih<m..

btstaUing the Gomnor Shaft IllSQlllh< JO- .tI;aI\ ,n ,he "'>u><: ord<r of n,",,,'.,d \11. ... pono-li' ............. "'" pi", """ 11'1<"""', hoIr In !fa< ~ ... ..,.

TIMING GEAR I CAMSHAFT REMOVIJIG TME nMlftG GEARS I. Re_ lIoe """!' nnl and ms;>SKmbi< tho dkT K=

!- ~mo .. Ih< ,~"" ~ .. fc and "'" InJCC""" pump <arn>luft un ,.tu.:h u.: ~ on: prtllo_IlDa!. lI"n",,, Ih:

~

1. Re!m ... !he c~kWh Ik""".., Iho <r.Inksb:r.ft ~

r.iDg Gear lItspeetion

-.... "'"

.... _---~ .• __ IS_. -*-

Card .. n~ ~ 'ht xc:n. "'..- outh and gar bYW"i<O>e::k IIIc de..-"""", be", .. ..,., the KlIer.= """"ox and , ..

""'-_liur'-'~ - ' .1:1 -._11_11..., - ... , ... ) - • .-1 ....... ) \lit ... -...cmbkd. dIc~k !he bKlla<h b<t""ttl> Ihe "." «'-' .. m<$II. [dlu tu' to cr.onksluft. '")«'""" pump 10 0::1«. and t2II>Iufll0 odie, --_ . ... · ... _ I • .IIIIIQ· . .... J t.I '.:"'1I.112i111)

RtpIa:c any fC3' """ f>ilolO mceolhe ~ 'fIOC'iic3oofto;

Installation ~fit the ~nr>k.n:.'-, CC'" 01110 Ill< =l:.Iult

Pt=-f't die V2!,.., cm>IWi P'''- and Ih: '!!"I""" flUrnp .~, gar:>nlO me" "'>f'<C''''C >iuf ..

r ....... 11h: ",:If ~mhI ... '" "" '''''I.''''''~~ ""I"'''':'' 1. Turn Ihe c-nnl.hoft '" "'" til< _ I ., hl'l<k1 'n Toe On

th< CO""""""OUUkc

2. 11I>I.>l1lhe v.h'C """"""fl and '"JCdoOft pump Cltl'l>lun

1. lruull!be Klier !:t"" '" th>Ilhe umln~ """"" OIl d "'" :ili~ncd ,."Ill th< rr=b 01> "'" DIhcf ~"""'_

~. a..:ck IhII tI'OC 11m,.., rPf'S "'" all In :lh;Q!TICN

CO " SIIMrGUII

~ I : 0 G ~ ©- 0

14

"" r-__ ", n..:; IDlE!! ' .... ~

If only !he C1II>SIt>fi " b<>n, <=10'>".1. ..... Ih: (olio" 10, s->~ ,,,,,,".

I. 0..""""" lilt cyhnlln he:.:! ~r

!. Pull au, III< 1"'>11 mcIr..

l. Pull OUI ..... ~ .... ~. Remove the ,¢:It cw: ~bly

5. Remove "'" ~ "<>PI"'" baIL 6. On", _ !he camWfl ....-mbIy

INJECTION PUMP CAMSHAFT RfMOVAL I. o..coru..a!he ,nJCC""" pumps.

!. Rrmovc Ibe 'njCCUOn pump :ouembiy

3. Remo>~ Ibe i= QiO •

.t. R<1"nD .... Ibe <h>I. "'ar "'va 5. Pull It.. >h:tfl "'" ,,, It.. fK>nI Old<

CAMSHAFT I PISTONS AND CONNECTING RODS Inspectillg The CamshaH 'I ... " 1hOrou~ Ift>pe<.-uM ...r the ,nJ<Cbilll pump .md "'" ,;01", =n.h:IJ",_ o...:k tbo OIdIum' , <""PIIng. ooo;h b>l11'Ie>r"'~ mol Ik om 101>=:. f<>f ,,~'" At.o d>«:~ iii< pu;h mel. mJ --

___ ~c...""'1Ie1M _ _ 11 ·1"1 ~ U_tUrn",)

IIIstaIliIlg The Camshafts.o1.iears

~ --... ..,-~

eo. "'" cam lob.-. and bann" ",Ib atIl11m "' .... n Ih<m on !tic: ,..''ttV Dr.kt of ",mo ... al

I'osII><>n llo< nml"1 rrwk5 on the ",:an all'" '"E <hem ""Ih .... ...,.... en !he !dIu gr¥_ After ,nstallahotl .. compIet<- cl>cd. >tid ad,""''''" ( ... 1 ''',ICC'''''' IIm.ne and v:Ilvc c~ .... -""'"

Ikln ..... , Ihc nn~, !n:m =eh p<»on ",," ,he """'" nn, pi"", U .. n~ Ihc (11.""" "'U"," lOUI.pull <lUI m" 1"""" pon In ....... " .-~; ro- cy<~ ""III <al"<ly Sl=.e<. dlSt1ll;op: .",.j "-dh~" ,II< _ ""1"- Althoul" me<h:utl., ~I) pte<> "'" . >'1<1 somwmc. h.unme<.",. j p .. ,on 1" .... \h<.e pt:..:""d ,..., <hsc~ IIISIUd. urn< should be Cllcn '" h<;lIth!: p!SIOn>.

."h,,, WIlt! H"ao SUD .,.- by u"n: ' hoo 1":'" Pl., ... ,n »mo., I,U OUI of ~ p1>lCn>.

\\'I,,1e !he "",OIl os ... 1' .. ...",. ~I>cd fo< ""'" '"l<gn~' . Inc! !he P'" rram c:><h iIdt_ If Ii>< I"n b""h ~11hr:: c"C1IIC1' Ii>< ""'" ""110. hr:: ~: ,,- th< b<n IJ mlS:l!llJned. th< 1"" ... ·,11 dod. '" bll><ia " ....... Ii>< r ... boss.

• •

§-~ ~.-----

~ .... -....... -ft.

PISTOlI AID CONNECTING ROO DISASSEMBlY R<mo.., ..... 001 pan.,osk< and !he oil..,run SIf3In<r

0uII: \he C'ibr>der nomber "" the <><Ie faec of !he b\J ...J of .... h COIIlIOCllIIi rod '" 1'""''''''' confw;,n, the CCMCCU"t rods.

lkmovclh: conr>eC""J rod o"P from each "' ...... and rod .-:mbI~ and dr. ... Ihe :wo:mbly bp"'-ard (rom the cylltlOel_ T:>lt <:= DOl '" .. low !hoc: 00""""""1 rod 10 ........ 1'1 <he: <nn\'.<hail pili >lid qlir>der. K"",p the ",,,,,,,,,,j pm. {~_n<;:LlnJ rod. rod Qp_ 1"""", «c_l cl3ss!iied by c~lmdcn

15

~~"\) --........ /Wior. -M~_ ..... •. .,., ... -/UZt.,,-,

~

'"

~. !!l

jllli = " I • ' iii;

Hili f~ ~

fj

HU . ' §.ltl ~ ""5! " ... iI III ~ ... ~ ~ n a: I"~ ~ ~! -j" ~

'<----- ,~ ~ ~ !i

B ~" ~; "

e~ '1 '.1 ~n f· = d i ~. in I • ,i ~ i fr i

t· _.

II f ~'!~p·I~F !!" i!J !J~!I .. g ~:ta g '" ' I·l ls°"'~~' ! ~H ~ -I 'I'" -i" '! - ' ~'.'.' i", :< "i !"!'l H]" ! . 'i '~'i "d i' ~ !" iI,. .~ ~ .. !I f ri [,iH !.;~ - : !; III If· .a -, .. ~ . ~~.,I" ;., j ~i~~~ it1[ ',<, ' .,.

~ ~ :~ ~ t~ §.l a"" 'I"'" . .;=lfl ~1l'f" ~ "! ••

P ~ J""u~ ,I ~~ \, // ~! ~B ""': •• I~, ~ ~~ d ~

~ ;~ 41 ~il~ ~ I I f~ 'i . 'I !I

., - i!I Ad ;:: Ji ll ~

I r ,rR ~J

a , " f ~

z f mn !i; . "1 II co

~ •

~I " n !'p ~

IJ' ;li ~ ~ i H' " Z "'.' i! '" ~ il: ~E;r ::g \; ~1 Q ~ i!i CI I . , } ... - II

• • , . . ~ · , '-•• · -, <

• !

I ,

PISTON AND CONNECTING ROD ......... ..,.-.. _. ,..... ___ ,w ....... _ _ . /k ___ .. __ 0Bt __

IrtStall1be Pistol And Connecting Rod Assembly listnJ: a pt$IOD nOJ ~ 10 .. "' ........ !he nop inlo Ibt JfOO>'Q, push !he """'" &lid rod u.embIy down .1\IO!he cyboder. Be can:fu1 ... 10 break !he MIS by t.t.cess,,,,,1)' l:tKick:tnl tho:: head of Ihe po<UlfL Noo: !hal II>< (""" m>rb 011 tho ~ 3rd Ihe cormcru.og rod OR 1iC'O-ard tho: fmnr of "'"

Coal. thr:: be"""1 wrfxe of Il>c ._nccun: rod~. ,,-,Ill <ngn,. 001. Fi •• .><h <:>p '" tho "Qnn<run~ md <bing "'10 """'h aurb Ih:lJ ~ puI "" Ibt bcr"", dt"""""'ilIy In Ih< ..... , ~ new rod does not h.:I,~ ~ nwl:. post'''''' Ibt ""' .. he> lpm'->d<.l filf pre .... nung Ihe be.>nnll f.om """',"" • .., "'" """"_

, CRANKSHAFT

IIEMOV" ... IISPECTIIJI OF THE CRANlSHAFT ASSEMBlY I. '"""'"" Ibt ft~...,het l bolls 1I'IC! rem"". !be ft)-whtd :!. l.oMom Ibt ~ pulley DLO -:I ~ tho pulley.

1. Remo>" Iho oil sui .... mbly

"- Rc....,.. Ihe IIWn be:.nnC caps. S. Rcmcn,,!he =ntsh&ft.

'- !nspo:ct 011 ~ pam oad rqtm or ~ any pons tIut ~ It- R.f.,. 10 !he m~ c.l1ooo for

''''-'-~ ...., .. ~-,.. ... -...__ a.t_...-. 1iIHiIr_. _

_ ... '_1011» __ fII" ~'GUr.

a..a ... _ _

~M

T_~··""I'U·lt~1

17

Rear Oil Seal Replacement Pry <Ju\ tho: oil ",,:oJ ""th. screwdnvc W p<n>'"'' "'" oeal m'" ,he ",[ oeoI .. ~

.~~

T..--; 111·15"" (6-1 • • .• ~"

CRANKSHAFT INSPEClWG TIE CRAl8(SHAfT Tod>cck .... mnlp .... ODd ...... n,.,...,w. fOtupc:tu'tl and OII...x.fCIDId -.<. the <bmaa of cad. ~ or ..... ~ po=! ohoukI be ....-..:d a '-pIa= .., !he o:nnkpa or _...,...,..,. '" IWO d=o:_ -,.- -.d -B- catb piat'c. lf ..w:wry . .. puod the c:r.tDkpont ~ MalII parnaI. 10 Ihe 1I01lioad<n;;t1!. If any =lq>In or IIWn JOI.IrIW 1\>.$ 1)«11

'""'" ""yond lilt scr".,'" Imu~ ~ the cnnbIWt

~CTNi THE CRAI&SHAfT 01. a..EARANCE Oil ~ 1$ caIcubIcd by 1oIIbno:tm, "'" diameoor of"," ............... 01 aar.kpa from ....... diuIo:Ior ollhc _~ .. rodbunn&.- Todlocklh!: ....... bea."'" tool beanI1p for capen"Z --aro;I QO,II-of.mur>d ... ~. Ihe .....,;k ~ of....,h main beanft. or rod bunn' ...... 1d be .........ml. AM lIS btartt>i cap .. f-...d . .... spec:JIed ......... IIIt&SIn .... beaIaI- '- pIaca .. , .... 1nI\b 01 .... btaruIa ond '" lbI: diI~ -A- and - B- eEh pa.... .. ....... If-r. repIxe .... wono be3rmt: ......... -.... If .... oil clunnce SIi.II ucuds tho. """"""' brnot. "en..:! oht cnnluh&fl1O the ",!I1 ~ and replace \he boann, ......... ol d>< comopOr>dUoJ ynden,l£,.

_.

___ U ,

NOTE: " ~~ _-luck 11m 1>< .... ~ r_ lit frl"""'" .., ""'Y IUldtmu.

--~ _ ''-1_ 1 .... "'--.... _,

-.... --, -,.:5" lit .• . _""14.115 · 01._ 1 ~lI$ • .• · .. 7tSlotcz._-cz._l

~"'--l.l$ 1,II lun _1I.mII (:lU U -~ __ l I~ III ZII..53t · n..- CJI ." · "~

.tI" _~ _ ...... _ ru_ 1 .... k_ ._tt,I_ 1 --.... ..... 31 · ..... 15.1. 5..5oH:1 ""''"-~ ... n · lI"' CU· l~

INSTAl I 'S THE CRAMKSHAfT R.da 10 Iho aIIouts ..... oJIuso3oon bdow.

-n-_ 'lU}.

L~~!~ ks .. __

18

CYUNDER BLOCK

CnJIB BLDCI .sf'fCTlOM Chd: "'" ~-tifIdc: bled: for <n<:u Old domote- If fttCCS..

o.y. ~ or rqU.::< It ........ !y. o....k 10 ... Ihao all or toOIi<1C waIer pMUIf' ..., "'" cloged and, 'f c\ou<d. m!IOVC WJIh ... "pessoed .... Of. "''n.

cyti .... Bore 0" nioas ' .... e ._

_ l.55IiI (t5 • ..-, -.- -'-11'-1

1.1iIW',=_ 2._m"_1

. ·_tu-I

IIITE: 1I?toIIJ IJ 1IIr.sJlJryforQqi.' ",Dr ~ "" tJw ...... _""e.. tJw ,,"""""'. ry/iNfL,. _,IIbo« m.onJ 10 "" ...- _=<-

Cyticder Relgillg

u. Ill< r .... "" proadun: ... 'heII rtbona.aq-1i1Idtt: .. Sela:t. fII<&a. .....

Il.llmm o.u S,. (OS) <If o.»nm os II. 101 ....... "'" p>IOa cbamelCf.

RdIon .. ru..sh~'" (Pabo (0) - (Clr;>nnaJ. (Ha>q AJgo....a ~n

~-- .......... • .-n · ~ (lJTl • __ 1 iA'OI

-n .. \.J7 CWC' 1OI01If --cn-"_'$I_Hbl,lMS

GOVERNOR SYSTEM ICSPECTlNG TIE: GOVERIOR COIIP(lIEJfTS

D' 5H1"" ad" i !ctioI W,lIItho re-c.< JaDOYed. 4i!1f t mbIc Iho "'verner.,.... 1m\. ~1Irn IU,,,,,,,,, Iho ~ ase. bo .... ID Itmove tho 11<: rod """" by the »do of Iho fuel pullllllIId do.,,,,,,....,. Iho ~ ham Iht I30i ~ all 1*IS!haI....wu ~ -lioWi" " I.al To mIlO>'< "'" k¥<n. pull out III< pgcMd po ... ,,"'hocII h>,,,, bca ckl"CD ....., Iho ro'" , ......... _ spctd corwrnI k>'cf. 1.-.. 1be baIto ilia fasoeft 11M: leva. >r>d wm. HOlt: "M>. ussl"'nm, .. ~_, ",wnoor a1M> ./wet W /"",rin, ... dot 1M! cast uk

~and Iho .............. !he Ie __ >r>d marlS. check/III Iheno ,... pn>per ~

Alia Ift""-m..OI .... b .....,..,d pia. dleck Iho !haft (or UIIOOdI op<nlIOII __ . C .. Iho o-nn" ...-.Ib oil btfore ,1ISQ/1inJ IIIem. Dc&cucM ""'" .. cuud 0.787;" (l(Inm) w><h Ibt i"""""'" ...., __ lItd

ImullIho 1<"""'" "PMI Iova IIIdIho 1pCed0llDlnll1tott SO Nt Ih: pt.y ""P bet ....... !he ~ ,S") .. """.macd.

20

TORQUE SPRING S£r ASSEMBLY Wh"" !he lDn!"" spnn, set has been d.-.cmt>lrd and IftIIlOCICd and def."" .. pa'IS 1\'pI'I«d. ~ "'" >djUjI III< I(Wqu< opnn, oa ....... Ibt foll'IWI"1 proot<Iutc

-"" _n .... /

--bumble ttIe TorqK Spriag Set Uw Iho ~I >em>' 10 lei rho PfOJI'ClJC"I 01Il10 1OnI"" """'" 0I0ppcr from .... "PMI r:- to Flihe spoafIed p-o. ,..... To ~ \he ~ ktep!he IOrq<.K! 'P"nJ sct In !he ....ucal po!itiOll • ~

MUS! _ St. lEA I'II:UEtnIII

n.... puI tbe di.ol puce pcd>o ~pnM "'" <pml <qIp<f .. !he ctnIa at .u aid ~ ..... a dial P'P' ....m , iCftl.llI'~ probe .. h>c:h dots ... coo ...... the IOfqIIC <JI"HlJ .. -.. JlII'hed lpllISllho <pUll ~ <no1

GOVERNOR La"'ft, "'" <hal Pit' lei. !IS condo""" "",-.nod, dqln::u "'" opnDJ >IO!'P<I' ~ 1I .... IMf Iht IOrqllC """ftl sa <UppM ..pnDJ eut. Rc» !he dclla:IK>II 01"'" dW PIIIt' .. tw;:b _.

~ I<> .... PfO!eC'_ 01 "'" 1pn"1 SlOppCI' fro... die 'P'ftl "- ( M~ ........ ohocIld be mD lqIUO£<!Iy for ... >«WXC mQOUI'C J For llI<....,..,h ... hod! do _ teQtI"" ""Y IOIqU<" "'"III :>:tIDOI. sa "'" JYQtKUOOIIO ~ "ah ..... "'" nIDI" 01 0 ", ..0 .•

An.. ..,.",. "'" xlJVSUnt'II up.. 1ho Iccu.... 10 • IOftI'Ie oI91i-1b (0 ' 10 I lq_ml

--'"

.... _r-s.no. .. -....... ~""'_$1 __ "'-'-

o

M;.> • ...-_.--S._.I.'_ 1.lIWd.l_

o

ItO'll: 71>u odj_ u tJa,w '" ."'_ "...r#!oMI .. ,,,., "'" ft7WnIW rAS>G!W",. .. ..,. /Iv /ft>Ib ~-ufto-i dw ,_,_ -t'j .....,

u.. III< follow,a' pro<:cdIn 10 ,DSQllIIId .".... Iho Torque .... '" I. Sallie opctd~ 10Il00 hlp odlint opcod (l6OOopm)

pao._ bJ idJIISU"I Iht "'p. speed sa bok. 1. T ........... oorque JP"fII sa "",,1m. £11,- <peeddtopl;

.... SO",.., fmm "'" "'17' Ilk spteO.

l. ""'" Il10. poiIIICIII. ...... b«:t h \OrqIII< """ft. KI by !he ",",",hod "limber 0( _ IN) l«~ "'" """"" ~ sa ........ POW""" ... 1111 the opec.;Il nul.

N .. 1.9 turnS (S.O KW) N" U _ (7.6"'W)

.a. )..wlllle IOf<I\O'I spn", tcI\Ql,.' eIp:lnd ~ II>< C>JI 10 pte>'a\l further Ioooc"",.

21

FUa RUN stlfNOID TIto: fuel run toic""'" " """,.",01 !WI .... en""" block ;oft <II "'" fud UI~ pum(l. 1k _. pkm.., pusht. .>pam! !he fud ~0II1ho fuel m".a-~ \\l>tt> Ito.

"'*""'" de etICIF_ 01 sbutI ~ ... &be """"" Sec E."GL''E ADJUSiME."-rs for -=bIy I'MU\IroDtI>

""-~ ~= VOLTIIGf: l lY • l ii'l De Coil _ 111.1 Q . 11'10 I. rr t~ '1'1IOICf: • .lS<. t.t1J1" fli. _'-1.

• ......... t7io

(1"0..)

ENGINE ASSEMBLY Install the nEi iiOSlat aad n.eiliiOSut Housing 1. Iasp:a!he IiIemIowI hous .... -.I. It>< housuo, pUc.

"PPl' ...... .ulan! 10 .... ps.ket ....ten ruuanbba,.

:.. Insull tho ~U'" ''''Ild> an4 Jell(\tr Olnd =-1 tho" ..,.a.

l. r...wl ~..,.. ~ and piket (!he okIlhetmo<u.I <lfI bocomo .~) ""'hen ,Mtalhnl "'" D<W Ih<rmoouI _ psl«t. ~ ~ ltuo "". 01 KAbnlIO bod! sides 01 "'-.&. A Ihc>a .", c::m be chedaI r .. P""I'"" apc_ by pb:q ... . pall of cold ....... IrICIIt><D ~ Iht ...... penQft 01"'" ....... ICI • bod ~ IbmDooIx u.o..Id ape1I _c>blJo (WIIh In>'el ... the order 01114 - lam (O.oo9t • 0.01 !1imm) and be fully optr>td """'" Ih: ....... IS bodin,

J.ItaiII u.. <'OObJII """'" ' M • 1>11 _ _ "--.. r ...... """'"' tZ · 11 "{1.5' U ........

Soc cocx..v.T ORCULATlNC P\JMP far .,.,..... 0I!bt , ..... bout&iw. oIlI><.:ooIoN pumJI ........t!Iy

-YjooSI tM ioo,;odia.lJmiD&. SooINJEC'T1ON lNlNG.

"'"""" tK oil 1iI_ hnckel ud inotaII • Mw filtn:; .... 'hrn .....u.n, Ihe ~ IilIer apply • ilion coal 01 c\un CDI"'" OIl Ill" 0'I>bbn pika. Tich .... by hand. Moow tho fl'GDl .up- - ntioc bncbt. ...... -r.......,'"'- D · ..... (U . u..ql

IaoIaiI 1M inuJit _ejfOLt ---22

1...aIl doo (lid _jKtiooo....u.s. [ ....... 11ht f .... ..... "' ... pop< Usc..".. oc:Wn ... -.tRn 1IIn>ugboul. '" Ihe _ oro.. as ....,." !til< old ~ ....~,... a ·"."l$.'-U_.q) SH R.ia INJECTORS l...."u .... Pow pi"", and conMC ___ U<c ""',.,10'''' com· pc>UlllllIII tho II'reads.

$Iw,.",. r---. """'" 1.1 · . ... . .. 1 ... · U~I

To IaI IN: pow pig"" '" GL()<\Io' Pl1JGS M_clhr n>eUr"", COOtr" C~ ..... ~ __ c..r .... _I.I.u ... If.:! · • .• ~

COOU>K1 Uw _ Iiae '" !lor ...po. ...... nled fud filler """ llw w.. II> tbt ioIjecDon ...... po tho..,... w:.:.Im, ,,<»lIen

COftMCC tho bq;h pnssu ... ioUe<tOr Ii-. from .... in;"'_ !len pump 10 inj<aon.. jk,lIW.Illhe line clamp ...... _T..,." ·U ... IU·U..q1

t.suI tho tid"",", lastallibo air iDtab siIaotc<;

!t1ooMd u.. ...p.e heac od •• ..,.... and ...pw oil ~r .... doe IIywIMd ..... . ....

The huo. udtaa,... ohooaId be SCI'"O'occd .. ""8"'" o-uNuL Rtrer CO EXHAUST MA.. ... lfOt.C\i'HEAT EXCHA. ... CER

ENGINE ASSEMBLY lllUall tbt aI, ....... ,.,.. (7.1iKW only) ~ dr"'~ boiL

A CAUTION: CiINI«IIhtIIlIbmuIIli Pl.rty. ShOllld 1M fIO/MffrkilliJstd, II ptlwMIIl (:Mfmf ~"" .. ". tbelJatlMy iIIt~ /be .ntffMt«, ~ tbI! ~Hts _ ....,1Ia

In$WIIhc tlo:nwor """"'" bolt Ihroup II>< aI ............ q (~) ,"'" "'" en" .. CUIl",_ S ...... , !he a11C1'113lOr "no paguon "" Ihc adjuslin, br.Id;ct ODd r~ Ltgbdy u,tun. AdjwIbdt~

T.p.:n baIh bolts oM rtth<ct belt "' ... I0Il.

~ ........ _ '~·" _ 1f.1· 2~ __ ) ... _ ... ..... _ , ·,O .... (I.2i· ' ...... 1

IIOTE:: Moh cmm.. 1M IKIu _ fNtfea1)-QliI~J ...w. rN alle"""", <IIOd ~"'''''' pWk,'1.. If no<. uuon or -""'~ rptM:. ~ ... <It Mttkd, '" alit" 1M ,we",,,,,,. See Al.1ERNAlOR r.;., «:Me. and 'aIIn, (7.6 KW oaly~

N U

23

Inst:oU ""' ............. pump and dri", belL 111>= M .. ,n """"" aj"runmt wnh <he =nk>.h::lh pulley a.:.:t __ . Refer '" RAW WATER PilloIP lrtS&alJ 1M oil and ,.,,_ ~. and ... ·itch.

IDSL>II th< """u _ . ImtaII "'" 1N"ok ... p:md and "'" p",Ir." _

RriDouJIIht mpn.. tkctrical h.>.mess.

~I"""I tho ...... pld. aha" .. manifold and 1M v;~ I:Ulk 10 Ii>< tytiDder bead. __ -..._ r __ la - Z4.--.j2.1-U .... 1

See EXHAust: MANIFOt.[)(}{£,\T EXCHAN'GER for "" . ""'" and insperuon. IA<bll _ "-~ aDd damps for u.. coolin, .-A CAIJTION: CIJtdr ~ AI: .,11 DC Ilfirill9 clJ/llHlClilMs 10 1rES1EIIBEKf) MfiIg ~tlcs .uJ dUgnms.

Gft>r .... '0f; MDWII m. ~ b;K:k .nd :w.<mbly wmh .. '~ «,,11.01 p<lnCL R<COIIIIeCI all OC """"I and recoar>«:I aD AC CONECboo!$.

Filllhc ... ,. .. rooIin, $)">1=1 ... " h "" .. fRett nuxu= >lid Ihe ..,""" ail >limp wnh lube oil (A.P.l sp«;. CF or CG~)_

n.. ~ ...... Id be = run ur>der load pnOf 10 ~"' • .wHn,_ AlIhi5 Um< rudjU$l tbt val "", clurano:c< on !he hoo c"i,ne.

EXHAUST MANIFOLD I HEAT EXCHANGER EXHAUST MAlClFOLD The .~'- ...... ,(oIcI. wtoch ...,.. ~ from \he oyhDlkr br.>d. should be IlIlJ"Cled bef"", r=sembly

1. Remove "'" "xhau<! cl_ .. from \he I.,....,. wrf""".,r II>< marufolcl. au. >rod unptct f".- aad> and drft<;,. Rr;>Io<:< ,. .. oded-

!. Remo"" III< • .t.a..st rupples. ,,100.... and plug< from lIE ~, ..

). Ronove,,~ conne<:1On from the rn<h of !he IIIlIrufolc! B<: .... to """. III< prqooer Ioc;KiM and ".,.".,_ .. 01 c>d> r,.- prnp<r .h~

4. EUII"" all p>N 'Of defects. com>s>on and"eM:meI replace .. fI<:docd.

5. Au</> "'" Ihe m.mJfakb Inla1l;lr ",,<II ~ liq~od de.>ner and ,,~thoroupIIy with IJesh "':II ...

6. Use . ",po C\UOO, to cI .... r II>< ~ Ihol """"'""" Ihe cooIIo:., =o--cry tan!< IIb.I.

1. Ausio OIIIft adaN ""'~ WIt and II'S OXIIICCUIIi '""'-

ASSEMBlY L If "'" ....... fold _ ~ as an assembly aod loft

,'''-''- ;. tall be replaced an \he cylinder ho:ad ID Ihr ~ order of .. moval. Do "'" raGe ..... pshu: ,...wI ~= --_ ..... _ zt·2' . " I2-I -u..q1

:!. If Ihe rnonifold has b<><a ~mbled. follow .... IO<pI

Od~.

a. Loosely anad! "'" clt:.o.ws to "'" cylinr he>d &tid Ihe mmifold usio. ne ... p>hu. Do "'" ...., my p<ka .....

10. Gr>duaIly 0"""0 • ..,.., fi!nn. 1(1 make ...... of proper 01""",""" of all !he pons. nus should be doric III "'= ~o< --_ ..... _ 21 -/' ... (2..1 - 1.3 ...... )

.. R<:....wt tho ahaIw connocuons and plup 1I'l1O Ihe marufold IISI., LoctiW.AIIU-Se= on !he 1IIrc>Ih.

24

Oleck!he ..-,fold p=""" cP ()p<ft \he val,,, ~ pull .. , II and m.»:< >Ute "d""", ",ben ",k_ M:d<. crn:un Ihe upper and ~ 5C:ds = In I""" .,.,.,ru1>On. If "") doubI.

rq>I:>co: Ihe """.

HEAT EXCKANGER Tho: hc..>t .~changu """'Id be nupe<~ on<! senoccd dunn, an ~ ..... 0'''''''''-'1.

I . o..co..nea!he bmcs >nd .. """" the b)sc: firunp.. J>O'COI'k. dnw> phiI' and .. nc: ono:Io Abo. .. mo',. II>< end fining> and g .. teu..

2. Inspe:t Ihe rubo (<;:as",,) fOf -.;or and denu, If 31 all ... spea :q>laoe !he beaI exchanger

J. CIeaII "'" ... y nne dd:Iris and prn<Ure = "'" coobn, and raw W2ler P"""'feS.

4. When raw:mbIinJ. D'1<UIl _ p<i:nd Q.nnp Apply """" lutncanl '" Ihr ....... p.k«> ;wi ", !he pclcocn and ftlll"1> a roo ,..wI !hem.

s. IosaII. ~w ., ... onodo

!lOre AU "'Ur~ abo.~ <1m be ""'~ 11).' '~I W M'" ucItanJ~' fQ a ~ aclwlJu .tt',.,. map TM:o • ..,[/ t:ho ur.;ia I~ <JIll! Dll"'" oil rooI~,..

6. Rcpam,!he lS5embIed 1><., e~changer ..... '" v."""",u hal rnUwiI spray _1.

AFTER COMPl.ETEI ENGINE ASSEMBLY 7. Roc"""",,, ~J hoocs. rep/X1DI ........ a. n.ecded.

8. Refin!he S)'Sltm ""Ih~''''' deWled :Ibo~,

9. Ptusur. = sygem >nd dl<ck fc:i I<.>ks.

FUEL INJECTION PUMP Ii ~

REMOVII: T1tE IMJECT10N PUMP

HIllE: D> "'" duiJuumhl~ 1M Ulj«tJarr """'I' ""k .. """""''''- MCnJ4T\ I~C11DfI f1""'P J<">J;~ u..;,JJ ht P'" /_d In- Q qtMJJljiLd tu~ '" an e" ... ",d .. d,.,,,, .. ~,., _ _ III. If W _ IS dtf«~'" " IS ,..cvmm.n<hJ dt~ "'''''' f'W'IP <Wt!!tbIy i>t ,.pwud.

I. o..oonna:. <he rue! IHJCC""" 1"""<.

1. Rcmo .. Ih< ""·rod dip <:OYC

3. Rano>. "'" ... -rod chI' and die I>e-rod

Disassembly I . R<mo ...... «oppet pl.110

1. u~ It>< dd .. ·cry· 1>cIdc. T>I;.. QU, ..... ,leI','cry ,-aI,-. ond~spnnl

J. kmo .. 1IIe appeI ""let and .. opper 1"11. ~_ Rema .. III< upp<l. plunger <pnnl • • Il;.

IIDTE: WAuI ... p/«iII, dw pl;mll~' bo., ... I. tkllW"J • ..u.. . • t<-. do "'" /OO .. ~ 1M adjlWlllll ~""'" r.nd p/llk for ,ad ~-liNkr. 1I-"IIm rJtm~ pam"""" iHm I?pl=.d,,, u IILCU'

"''' 1(J ............. fo.tl "'JOebOll 'i"""lrl)' bv .... /011, Q pwnp ~_, IWi «'" boA- AU porn ./vu lin' ... ,,,a,old from riot pllm{>

<ltoold i>t Up' c~ In ryluuk", anD """",,,.d !II ck.." j "' [

25

IIOIlIUI sn.,u -----~

_-I~ I"OSW @

~~~-If-. -::: ADJUST'IIGSIIJI __ t§

='-----~!:"'...:= Injection Pump Assembly I. 1= !be: p/Ut>1Itt baml llllO "'" h" ... "., l. InsuJl tho ddioay ....... ...:1 ,">I .. <p'UI1_ Ttmpor"" l}

upuen \lit hoIdrr.

1. Wen Iho torIUd I1rl-~. Luen Iho CO<IUI>I 1'11lI0II. All", the ..... I<hmart \III the

rack ",th thai ... the pm>O< <pIUIJ upper teal.

6. In"'" !he plunv< "",n,_

7. Ft. the Iower !oQl lQ lilt pIun,. •. 1IIKI'1 II>< plU"I" ,"'" !ht barrel s.de..

8. Depus!be UWtI rolla >=mbly and ms,,,,n u.. .. opper p • •

, . Tip n "'" dol;"~ boid<r 1JoIi.err_~~: Z$.3 · :U . ... (U·I.t_~

FUEL INJECTION PUMP I INJECTION TIMING

""""'-

IftStallillg the Injectioa PImp In>WIIht .. p:uon pump .......,bly in Ibc ,.,..,... ord<r of

'""""". IICJTE; \l<Jot" illsUllWtt dot p/J<J!g~' b,,,,.,t ."Z"ft rN. <Io..tf PUO <III IN 1touJu.g tid • ...,.,. dt. g,O<7". '" dot _,"I. Pom- rN ~.r so rAm dot pan IIllIrIMT nmrrp on '"' jIllngt f«a w directi"" opposite", Ilw 'ad sik. /&'1"8' dot fw! Iwk .... illl 1M pi"",., "'ad.J Ioftu <M~ dvd "" p"'p'r ....... c_ n"",,&,.

Wbo:n~, the ,nJe<'ll<l'l piP" """'mbIy. Ioo>rn ..... POP" cllmp. When bprun, Ihc .... at.xlI end of !he p'p'. F'P Ibc noaIo baIdef Of ddlvet)' val", holder wlIh ''''TellCh 10 1"""'" rt from bei., rumcd 109<lhc:r ,.-uh "'" ""'- AIoo. laic. are ... 1O.now dutniElt (Spill naringj nws """'" adjustment II ~.,."".d ,",1111 the <""ncJrm:~ la" in op<n!Inl oondll.an.

If II>< "'"",,-0 fuel injr.UO<1 um'", II noI prnpetIy ~. the: ""I"" WIll no< 0p<:t31r prnpctly and may be difficult '" SUI\- lb."" tho: "'JCCUOn okhnry r= cbodcd by I well-

26

nublt<h«I ruel InFu,"" .nop. AdJ"" the: .np:tJOtl :IS

fallow<:

.ore TNr t~/ m..:-cff "",,, "' .... bt '" 1M R1.. '!'> P<"'!" 'hi« ~l dot <Jd~'" tK """,.1 .. ,II """"from do. [wI ",~pwy.

I. R....., ........ lugh ~ 1",,1 II ... from bc'''''eCn "'" No. 1 .nJ<Cl« ""'!hi< 1"0 ! {u::r <k~very ...... , . hoIde,_

1. R"""",.!be No. I fud del"..,'Y vat> .. holder 0-= o-nIl' >nd <mIG'" !ho: ddm,'Y val", 'P"'nl benealh Ibc hoIdn.

J. Rcm<W1 only !he delrn:ry ...... ~. hokIc:r and .. _ Ilr lop ~ fuel II ... 10 !be del" .. ,,-hoIdet An.:b" SO do: end ... 1odo .."weI"""""", '" Ibc fU<:I,nJ«'Of IS paoM"" ...... y from the: """"". ~J ... ,11 !\ow fmm """ bn< dmmJ "'" 1lmI"I cbe::t"

ItoIm "'" <.11""""$ cr3nkshaft 'ft '" 1IDmI,1 d1leCOOtl of """" bOn '" posIIlCOI ""lOll 1"0. I '" tho b<[lDruOJ or '1$ rnmpt< ...

"~-M.,... "'" llw<dc I<'-er 10 lIS full open ",,",1><><1 :ond opor,uo Ihc dcdnc Wi pump. Slowly l'OU/l: Ihc ,ranbtui, dClC~~ (1$ ,..e.....d fmm "'" fran,). taidt'n, fuel from !he 1"0. I Iud line. ""01 "'" ,_"'" fud coonpktely <1"1" ~ .... ,nl lno dnps). AI !Ius IMWII. cbe 16" BTOC urnlft, marl; "" tho cntWNft pulky obould be d,=tIy a1ifllOd wnh the urn,ng ~ an "'" fmot of Ihc JU< ca<c: '" .5 degreeo. If !he s;>ccilicd ,ftJOc",,", timing (16' B1"DC) ~3lInot be ll1.lIocd, IdJU<l "'" tmllnl by '''''''' .... ''1 or dct:re>;SlDI"'" """koc::I.s of.tum maIenaI under !he ,ftJCC'IOtI pump"' """,n!"

"'IIIlmJl< 10 chang< the ,nJ<C""" PfN"I pom<. (lw,pnl "'" shim thic:koc::I.s by 0_(1).\ mel> (O_OlmmJ d>an~ Ihc "'JOCUOI' "rrun, by ~Jy """ depe. To adv:mo:. ,lit \JJD1Rg.

dEcruso< ""'.tum IhIckroen:t< faI'IJted. To rewd!he urn,"," ''''''''''''' tilt >Ium ~ a< falurrcd.

FUEL INJECTORS RfMOVIIG THE UU£CTORS

.:rre 1~_brS<"'V:M"" "cItdrr_" """_

I, 0...:' "1 dIO lIeb prWIft I""", Iitn!he .. ,.ncr. m;I IDo:oao !he II .... III ""'It ~ II> m. .. ,..,..... pump __ .......... of Iho '""lOy fli III< 1IIJ<CI'It$."'''''' brndiooa m. luon

2. u .. ftJ' I7mm IonJ _Ui. f'tIIIO\'t Ih: f"oJ rewm I,,,,, '" IU mur.ry from dIO lOp fli Ih: '"JOCICn- Tw (.>rC IlOl It) ..... !he 1...0 ... .JImJ .....tlen ;!lid baDJO boll dial ~ III< fuel ~ w.: 10 udllIIJ<CIO<.

IIJJl; a-. dw =<I <UfJIUtd dw ..... ofdw IIIJ«*W ,,- '" /tfIHtJ "".., of dw rylmMr Jwod ... Iotlp pm'ml ............ '" ddlru frOIoft;Jl"'l oIoom """ riot IIIJ«I'" Itoh If Iv U!j<€ ... , will "'" h/f"'" ~""" U Mid .. ltv €"'*"'" boUld "p or 1M 11U • .....t dw OOJ«II" udt '" s.ult ..... dw <Wdofdol 17_ .u.p_ ... ""O' ... jrT< rI and dtttIllft" <>01/.

l. n.. ~ IUl$ ID m. cybDcIer head aD • ooppcr seal, "" waIbor, Thi> wzhor IhoWd bo r=<Md ""dllhc "'J<CD MCI repIxcd ",dI. _ wuber """"" "'" "'F' a if .... esuJled

UCT1III1IS11IIG L V ..... !he oozzk 1ISIo:t. ct..a 1ho "!'Ol' pMICtD andlllF' ~ IW\IIIIJ fJIUIOIR 0( nGUk m;I. If. w:eecIJ dI< ...... ~ odJUSl ... replace m. ....uk. \Vbo: ..... '" nou!< ....... lib: 1ho followmJ p""' •• ""'"

A CAIITKIt n..,., : J In' &-.. ,....m. ., ., ... ......,tNr • .,; .• ..,. ..... .. .,.....,..--. d • .,..,a-.1l1t ...", .. b! Ati , 1r..".gaao/IIMJd I§.

a. If "'" diad fuel of the IIIIZZio ...... II ddcoIam!. ~ ....... dIoO <aIM ....... cltaa ... rqIo<e "'" ~ ....

too. Sec !he IIOtlIo: IISIo:t ... d ..... pIKe ... 1Im: o:hac II ., .... On

<.. Mouet "'" oozzk and DOW< holder ... "'" D<>zzl< -. ... Ibo: 1ho fuel III "'" appromRIIC IeIDptnIIft

of6r F(lO'Q .. epa. Ita< _ kva fli IIOtlIo: ....... ~ ".,.... '"

bleed !he ... ;., "'" now. Ii-. Ib:'I _ !he bIIIIId Ie>u III ......... of _ SQ"Oi:<: pc' sa:ond ...tIo1e rud-

ina Iho 1II)CC'lioo Jt>ru/IJ pms=.

""" nm.

27

Inspecting Spray P~ttem I. Openoe Iho h>nd Ie .. , of Iho noule: ICSIeI' '" ""<"'~ 0(

..... Rnlkc pet ~ to .heel ,flho fwJ .. ..,.....,.. <01'

"""dy '" .. auaI ~ 1\ nouk .. dcrcro... ". "',..:u IDol ,. M obi""", ~ .............. >CpOf"'"

00>pI- """" • "!'Ol' ID otc form 01 p>nodc. 0:0:1 ...... a defca. ThcK ddew may oomeu ..... bo UU>aj ~ do,· f'ftl ""do 6.IsI :and. 1IIt,.fnn:. 011 pin> sho.IId bo t:UCMI~· cle:w:d bel ..... IUlKInbly (Un: ....... 1d bo!Ken DOl 10 "p<ISC ..... sb .. 10 dus <pay as • may ""an_ Iho o:lrtI wau>t~)

~ llOI I!IJiii • • ,

, ~ .- f~ , ~

''; •• , .

~"" ,

2. ~ Iho ~ fli 16331b'dr' (llj q.'<m') ",noalc by 0pmI!I1IJ !he hW ~ .... , and cbock Iho dnps fran Iho -"" lip, 11 ,t dnps DO' has • ~ ~ 01 fuel 011 !be baao:m.;' if • c:ddofccb .. __ be

repIxcd.'" ,..., uruII am<JunI of ",." may-..mPaI>I .. Iho lip 01 ft 1ICIUIc, hoo:<:~ ... does IlOl IDdic:IIc • dorm.

The 1DJ<'<1'CW' surua. ~ for "'" '~,mon .. aljuucd ~ . ,ncIUS1", ... dec,..,..,n,,,," lh>ck1OtSl o(!be odju",,,, .... m.

The shim has 10 dilfereN tluckneut:s r ... """"y OJXJ20 ... (Q.Oj ...... ). b<!_ O~9uI { I..l$Irun~1O o.OI'i69m (1.7"""" Wod>cadlQOO?f)", (Ommm) w'" _ ........... I'ftSJ'ft" ~ lppItWIIIIIIdy ?l.llb''''' \5.0 kp-). V' l.,.. replacmJ!be slum. piP !he reIamdIJ ""' .... """ and mno-c !he bc:dy ..,dI a wrcoch. T,pw. lilt m:uIWl, ~ ... IG !he spcafl<d IOnI"C:

_nee-"

FUEL INJECTORS DISASSEMBlING AND INSPECTING L Camp the: nan:l< hokk:r In ~ V\Oe. dlen remove thc:

~OJI nu~

1. Rcmo .... the ~ > rod.

l. CWnp tho nan:l< hokk:r In • VI ... "'....,... the nou.lc: nUl Ih<n pun Ihe nouIe 0Ul.

4. Oe:u. thc: ~ p:iJU .....m c","" d'eoel ruel. dlen ternOVe !be arbon adhcnn, 011 thc: n.ouJe..

NOTE: Do "'" lilt G _Id :ooJ '" ~_ 1M c"rt.o.t.

S. After cle:w",. check 10 .... if"'" needle val"" carrr< -.. U\lO lilt .:aI"" oe2I by ItS ""'" _,ght who:n <ctlJng

"'" ""zzk body upnJbl pOS""'" ond l...mtnl ~ vol, .. ,

6. a..:cl: m..r. Ibere IS no ilaw or od>cr dama", on n'WIDI

..m",,~ :and <!idmJ surf-=< of the ""We body w Ihe aecdle ><01 .. :uId. if p=Cnt. :q>Ixc tho nozzle :I>SeIIIbly

28

IIISTAllING I<»1OlJ thc: no>nk 3DCI ""Ule holck, 3O>cmbl~ In !hi: ""n>C orU<r 'Jf r=>C>v.>I. v,bcft " ..... n~ the nou.lc: >nd nan:l< hokk:r ;wo:mbIy . ..... _ - <Oppel' "' ........

ASSfMBUHG .......""bk in Iht m'mC order of w=sombl). ftOIJng III< (01· iourut, poon ... I. T., ,....,mbIc dr DO%d< and nonk holder. fir>I ..... mbIe

!he 1"'= >dju.unl nul oodc. and lempor:L.,ly hglun thc: ...... MIlUIII thc: nozzle ond "" II>< ~ ,':>Ive., _ p<><_ 111m n'IOImI II>< DOZrlo nu~

2. Aher thc: nan:l< >nd nan:l< hokk:r have bom =nbk<L cl>c:t thc: inJCC1>Ol' wrullJ prn<o= _ <pr2y condit-.

RIB. un PUMPS 11>= 1$ DO ~ I'EIlwmJ for !he: ooIid stXe r ... 1 hfl JIUIIlI'- Thi> P'IIIlJI is ~d dunn, thc: .un ~ .. un prdIea is pressed.. It. dwmct tJCltmg can be hoanl .. h<1I\h< pump " opcnlDI&- If lID I>CbnJ is heard. check thc: elcctnal c~ If rho P""'P ~ failed. <qIIace 'L

Some arty made] ~OR and _ tt"n<J3Ior> ~ , ... JIb 24 YOIt <ysr<m< a'e cqwppod ..nil ~ furl lift pump , ... bid! ...... a repllCc>bI< ~hn. A, .....m...l. replace <he /iIlei' and clr;m thc: pump .......... >tid the tl<ctnal ~ This pump. ,,-hen opcnuna pmpttIy .... ill ....., nW« • distuo.:l tickln, IIOIOe.

Fun 5IItIISTlll AE~_

GLOW PLUGS DEstRlP1111H Tho Jk>w plug; ..., " .. cd 1Iwu£h Ito< I""he:tt "*notd. _II PREHEAT", pmocd Jlth< mnlrol panel tin< .a..:nood shwld -obck- Oft >nd "'" I""" plull should begIn 10 iel""'.

INSPECTI ON Tn 'fISI'C" tb< p/<.I¥, ~""'''' Ih< .1rcmc:I1 !emun:.i ''''''''''c'''''''' thrn Wl>CI'C'" at ur>.:bmp eICII plug from Iho: ~~hnd. .. h<:Id. 11'Io<ou.;hly ck ... ca.;h plut. up >nd thK.>d> ",m. ... ~ bnuh >nit dUlunl soIullOfl to ""no"~ ~11h< c.:rilon "'" ool~ ... Willi< clelrunii. cum,,.. II>e lip for ""=' md bum cm5>OOI, If n has ""'<I<d too rnudI. "'pi""" Ih< pin ..

run .. An I<:C'\.nIC "~' IO IC5IrJoo.o pi .. " .. WIth .. oI:n ........ Touch one prod to ..... ,10 .. ' pi",", ,,-'''' c"",,"choll. :trId !be CIIhe< 10 tb: body 01 .... ,low plur. :>S _II. A rood I""" pI","';1I ha,," a 1.1). to l>ohm re:us<anc •. Tbos IIIdhod can be 1&<1 .. "It "'" pi .. ; III or QuI of Ill< en,,,,,,, You an oho Uk an "lIImeCU 10 lOSt Ibc pow •• drain

{8 10 9 """" per Pur}.

A WARNING: 1JMse gt_ phIgs IfIIn 1II!CDHH!""1Mt " ~ 1l1«li. & umu/ HI: fG bum r-~ MIeIf

tating * p/IIgs

29

R.-.... ':olllhc plug< In the ""I'",,:md to:>I tbcm '~~In n." pI .. p should ~ ,'cr}' "'" ('" Ihc: ","",.01 onJ ) ""h,n !O ,,, ~ >ccCDoh If lh< pilip d..I , '"' ... "" .,.""U). ,;I>c..~ 'n" , """' <'mlIL .... ben ""o:.:t.llI'"~ "'" p. .. ·1'Iug,. US< .>.",."" ",

..-pound "" the Ihrc:ab. _".. r .......... ier'II'O 1 1 -U", .. {1·l1.~

A WARNING; Do.,tftll' . glo.,III9I111IwWltn /Ua 30 ""CIIlM

COOLANT CIRCULATING PUMP DISASSEMBlY I. Rl:rno ... III< pump pJll<y boss by .... OJ ~.wppon >ruppon black and pre"'-, nnll pI",,,,..,.j pn: .. QUI

INSl'EC1lOO Inspecl !he shaft. beaM,. and Impeller. Loot for aa::b and danJaCc.. a,."k ..... """'ut, S>Sb:1 3nd 'DSpOCIIhe In,. se2h and ...wI end ¢tIS. R<pIa« any J»ltS th.oI. """, . .. ~ ...

ASSEMBlY I\..anhI< Ihe watrr pump ,n Ihe """'f"$C u<kr '" ~. "''''B "'" (aI"""'OI pro..-.d ..... I. Fin blhi<ml ~ (luluum ""'" NLGl No.2) """ ....

follow"'E P"'5"'00.

• !WI beaMp • Appm.",....I!' 113 <pace ""''''ten bod> ball "'O>I1np • Spa<:< bc""'<CD "'" ball be:ann~ <>nil " ....... boflk pl •.

::. Apply, "". ro;II of <ng.,.. 011 '0 !he press iiI....,au 0( the ~tet iaI <IIId press It.: latJet end ,.'" "'" prnpet >p:n"'~ of !he pump ...... , a tubular 1IW>dreI. (49 06:>6 145)

30

HOlE: Do "Ol Di'- o<L '" grrllM U} conlnmHUJU ~ J"'1iJ&n of rNr ... """,r ""I '" 1M g'1lpiu,~ ,.,.",1/ ~..dl of tI!t.p""g.I«;,d~J ua!.

J. Ah ... !he ..... , pimp ~ been :wembkd.. cho<l ,j !he pwnp Wfi rnwos vnoothIy_

RAW WATER PUMP Dkassmbly Th< pump. .. rmIO\'C.d (""" .... en" ........ ,n loa", hoo< ""'"' __ nIpples 1IftaJ<d _ lIS ..... ond 0IIIlet pan>. Tbe) ~ be lor. • pI><c or IOn ....... f Ihoy , .... tf.,.. .. -1Ih .... ~d .. orl .. lOll' NIle Ihc pan ~ >nd po$~""""1 ,-I. ~ ....... aM< pa-~ r;:o..cr 111-. _ .... - ... ......

• Ilt: R'~ __ fIl t{ _ ",,'f' pkuI ps.U/ .. IK_ --u.J.. ~ ... ~ f:- "'" ,...,., .. ___ rl, uq ~ ,...u. tab.w'Jt4 .. .. ,"" fIIIlJJ rItI: JM-P" ~a[, drJ dw ,...ttl • ..JJ Wuot t»td _ lot .......

1. RrmIM= ..... mpollor ",-!Ih II, <ktw ICI'ew &om .... pDp -. .1. ~ II>t ICRW ..:I IQI"" waIhcr ..:I ... _ ....

CIllO from !he pump lIausmt ... ~!he mamollJ nIIJ.

.s. ~ .... P"'I'P h:MIaJ. '" .... __ I Ibn.,. """.... orboo pras. IIId .. l1li a dnfl.1ftSS out .... sIW\ >nd I:aruIp from 1ht I"""P hDIIMDJ.

6. 1IIo'1\h .... pump houo"" IIIpJIMCd. puslllhc .... 1s DIll of

.... P""P """"""" I'11III .... " .. "".Iet s.ICIc seal <lUI .... impeller ... "'"" btl .... 'pa. sod< seal 00II .... bo,,"n, iide.

1. SuppMinl .... be ..... '. , ...... n«. push the WfI OUI of "'-laspection I"","", aD pAns and ~ Ihosc 5IIowuIJ -..- Of o:om>uooI.

""-.... ty I. 1:a$UII .... seals """ spacu III .... p.r!'9 Ioousm, PwtI ....

IIIIpdIcr »do tal _ cho ~. Ro:uo Iho pump..:l .....J11he opoar IpIJIR !he IAl flOt. Push .... be>n", oodo seal , .... Ihe "'-aI. rn... .... ~ sIIIe. mrE: n. utJU'jItII sa4Mu that ........ pNQutf_

--«,,'ou _1fI ...........

1. IMl1Il .... oIuf. ",0<> .... ~p Suc>Pon .... hunn" .. """'" ""....,.. rrn- I'U<h .... ohJi ,Ill(! .... bQnnp. ,........ m. aI Iho Impel ... ~ sloe .,.j _ ..... b»t r/ .... ..... c slot. Push .... s/uf, tIwuJh boIh '" d>t be""",... ft...n ~ c:rl ...... "" die 1bI-iIdaI eoocI of .... iNn c_..:Is beya!d .... oe:ond b<lnftt CCOO£t...,. (WI :! 1ft

(J ~ m.lQ) '" 1Il1 III ( .$ """I

.1 Suppcn .... pump IIou$IaJ .. Iho unpella !.Ode Apply ~ om3Il ........... of peuoINm Jelly"" .... .. aI -• ....... hps and 10 1100 m>peUer WfI. C-fuII) IGIUII !Iv .tWi. ~ >lUau", "'" ;o:aIs ..... 11he ~p conIEl "'" IuAm& from .... beoruoJ e<d. UK. pus/ua. I<lol m. ...iJI push Ihos sIAIi IIId .... boonnJ ~ ..... .... pump """=c by ~ Ift!o5I" IIpIOSlIhc _ -..,. ~ f'Inh II>< os.ICmbI) -.0 II>< hcoIsanl unUll!>< br.zu>3< _ fully • I!>< ~ I!\WIII!>< m:u ...... ""1_

.I. Pos._ I!>< cam Lft I!>< IIouomc >rid _ M • plxe wnh the ocrew >rid scab", ... 2$ho:r

IIlTE: UU" .,."./1_ tJf Prm!<JlU II / "" dw ...... , c"",, s..rft>« DIId XtrW d-..-u. R_ ""Y _m fr<Jm IN ""P"u",r ""....",.

50 "W'Y ~ lirJ>c Iilm 01 silKonc Of pcuulcum )OUy 10 !he """'" ....-face of !he """""I fOf "'" Impeller NOn: CDI1I mJy dw ... <focL. '" _ --wh 11U1Qi1 rJw ""P"Uu wr1lL 1lL~ ~ SCm.". PIUA dw =t ........ w o W """"'" .. ,,11 dw tin"" SCm." """"'l '" ,M Jlot"o! dw dri""sMfi.

6.. 1o<Ul1!he aM:f psI:eI >t>d _on. and $<CUfO rt>cm .. ,it! I!>< .... co-~

1. RqIosJtioo -.I u,h<eB I!>< has< IlIppIei.. ",","mbk the pump to the eftl'.e. IIId anadI Lhc ~

---. ~'- Ill. WATBlI'UMI'

31

STARTER MOTOR

n.~ JllUfD ~"" be roughly d,,-ded ,",0 "'" foUo .. Inl >CCU<Jn>.

• A moIOf...a- ",""'" fOr.er-...."., <in .. _ ......

• An """m""lInl elu .. " !I<:ru<XI " .. t".,11 ~ml" :1ft ~ n= "" ...... """ -.,,un, mol ... OVCITUfl :a£1<r <L>n"'~.

• ... ~Kdt !«lIOII uolcnoodJ ,,-11><:1. Ii "P<r.ot<d """"" :>::",.

aon" "'" .... =, dutch 1hn:aJ!!h a 1o'"ef.lTd .. 'luch ~iQ Iood =' ". the ....,. ...

11>< SUi1eI' IS . ...... typ< • ...wl. h,r.-"""p and t<C>lkd, "'v--speed ,1IIefIIaI.-redu<-uon swtet. Tho pon"'" o/I2f. IS ~ zxe from !hi: mDIOr .tIaft. <hi: ponton >lido> only OIl "'" po>IQII $IWt. A rWuc!>on:eo: Utnstaltcd bet .. =n "'" mot<>r """ and • poft lOll.tWt. The I"R"'" "odInl!»" .. '"'" <<posed 0UlUIt Ih< =r<o thaJ. ..... puuon IN) .lode <tr><IO<hIy "',1hmiI boc"""nl r",,1ed wIth do& and aru>< The _ $h>h IS supported ~ both ends "" ball be.vmi'_ Tho: It>w m<dwtrsm. ""IIt" and " .... """""" dul<:b Inn<r om;wl .... ocIonuaI to> convcnuooal one.

AIl.AJSTMENT AHD REPAIR If any KlnonnaI..o.y " found by !hi< follow' ''r JeW. !be WI1ef _ b< cbsas><mbl<d and ",p;u~.

Pin ion Gap Inspection 1. Connca. ba&kry (I W ) bcIWttn Ill< SIm<r iOnn=l S

IIICI the mncr body ...... II>< I'ID_ dr,,~ iIIould f<lUIC --... !. t..i~y push !he pin"," back and ~ "'" « turn

W<lU (ailed puuoo I'JI).

3. If !he poR"'" , ., ... IlOl ""d'Iln !hi: <undord ~re. (O.s '" 2.0 mm). odJUSI n by 'r.:n:.l>tn, or det .... '!IJ lhe IIII!IIbet 01 <hun< on thc <Okaood. The PI> is deaused 21"'" ourn/:I<T of sill .... m<:tUOeS.

--

__ L_ u-u_

32

No-Load Test I. COOflC'Cl thc """"","", ."OIIrro:l<r. :n:I1wtcr) ,,, "'" """',

"" ,U\btolcd.

2. "''hen'"'' ",,>Idl .. d''''':d. III< PO""'" ""'" ",,1lMlc .-J Ih<: <Una" mitll nm """"",,,y tao lOOO tpm or mon: I. 11 "'" curnn' or sunor opoed ,. DIll of ;,pt<:,f .. :" ... " ,- 1,1, ...... ~rnble "'" SIOt1ef >rid repair lL

SOWiOID Perform tho: foUoWlnJ I<:SlI.. If :my ~ .. resul' IS 1>01 Widacl<lt)'. ",pI:occ !hi: ..,ltnood ....:mbly

I . Inspect tho: >Oknaod (01" <<JI\Iln""y bel""",," .. rmll •• h ( .. ) .:tnd t-J .l1Id bono .... n \cm"naI; S .l1Id tho: bool) lnd M 2nd tho: bot!) "I"II<n <IIouId be no <ont'"U"~ I"""" bel",·",," tem'UrWI S.l1Id M COftl'.~It)' Wlil be 'Ound bet",..:. ICrm'~ S ilIIod tho: body """ """,,,,.j M .no! tho: body.

II01E; DUroNfN' lit< ... ·,n ftr- uTffWltll M.

2. Connect. b:Mtcry 1<1 tho: $Oknood·, 1CrnI.n.a1 5 '01" I_ I and /lot f(r ( .). tto .... ~ ""·'lCh In tho: - lad ~nd .:I",.; ~ The PO""'" dn .... ohouId .xoeM fully out.

A CAUTlOIt ~ /WI wtr ~tt6r1 t:lIrtmt fIN "'''" tIYn fO$«lllHb rIhm ~ IlteuWlHIM.

j:< STARTER MOTOR

-fo! 0)

~

JT~~: e e un~

~OIIClff

• J. Ho/di.tJInt '" iIh " bmtf)' ~ '" !ho >IlI<DOod ........... S , _ ~ :mII 10 Ita< SWW" body • .........or pull",. "'" _ f~ llIe """"" must <anaI~ :II ..... ~ __ ....... tdc-.:I from ~ ... -.d\ ~ __

..... ~

STARTER ASSEM&i.Y I. o...:o.-a Ih< ""'" from doc soknotd 1£rnIIB:oI /oj I-)

1. looooon .... , .. " ",,..ws '_ft,ft,lhc ooknood_ RonlO"( o;ho: ~ >Ucmbly

1. R."""", "'" ,...., ...... Ihrouch boItJ _ ,_ ""~l fUlClOUl, 1he bru$h hotdrr Remove IhI: ~ tncm

... \\'1Ih III< bnNx:I pulled ''''"2)' from ""' .............. _ die yob and blush hoIckt -.nbiy n... pull

"'-~ S. ~ III< """", pry .... $nap nn' ...... :mII ~

"'" ... "dI<r.

'- u"" .......... bolu :and "'_ !he cent.,. tn<:kcI.. AI "'" sam. h ..... u.. ",,,*,, for !he 1""'011 shott ."" pllY >dJVOllnOlllwlll.omo otr

... R~"'", <aL ..... <111 ~ No..-r ,~""""-"'<d '" ItIoo ",.boo"" .... rrwo.>J M ,., .-l 10110;: -t:IrIC< Iood} ........... h pu;1 .... It.: PO""'" , yQ, 11>0: po ...................... In It> ""~I""'I""'I'''" ",hen rcl<.>.cd frnm hnldlfti by 1IanJ.

1. Pull_Ita< ~ pie''''' -' k,'n ",""I' flOft\ ....

"'" """. &. On lhe 1"""'" >Ode , pi) tho 0II.1p nft, out.:and pull_ ,I><

1""'011 2IId ""'_ Wwt. ,. Ala.-II.""dlho __ . r¢~ .... b3Il too"",_, "'AA

~ beann, pill"" II IS ImpIIHibk 1O ... pba: the toll bt:."'1 pn:u-iaod .. Ih< m.. brxm. If tha bt:lntl, No ....... oil. topIa:c .... '-' br:Io;:l>n ~

-- .,re ItUp«I, ckot """ f"~J ",piau dwb,..Jt, .... = y'_< """'-t """""',..

STARTER MOTOR STARTBI INSPECTION

Solenoid Imj>ect !be >Oknood f<l< ~""""""Y bel' .. ,,,... «nrurul. S ..., M :Inc! brtweom ltnruooJ. S >lid bad~' "'" <"""nu"~' shoulJ be found betwun S and M Conunuay .hould be found m",un S """ !he: bcldy ::md M :mil the bod>

laspectislg !be Armature I. Cl>ed: m. armamrt "" ,'" ~ ~ 1nItt. If ""$ $b(:n

=I£d, JqU<c .... ~ Abo d><clt fOf ,,,,,,,Iocion ~!he ~ >lid it> Wft. If poorly wuloled. ~ !he ZI1IOIUI'e.

1. Me.nun: <I'll: CorntrulUl(l< OD. :HId !he depdI a( ulldcrcul. Rq>u Of repl>cc II if the ~ Itmn .. e~ !ilio c!uk II-.: cornmUI3IDr........x ouri""" far mn._ >lid rougtoncs.>. If raug!I. pOIl$h "'" commut;ll,. " ,III nne -,,",

~-__ l~iO(3I.7_)

~ "..,. 111 1-1.1 ... )

34

Brush al'lll Brush Kolder Inspection Cbe<~ !hc: ~ If worn "'" ~'OfId "'" ,.tv • .-", I""IL "'pl3CC !he bru<hn

--_ 17_ lf.Mt_, ~ ,_,12]1,] iOJ

:t. Check !he bnIsb 5p'mlleMlOfl. A wul; at defC'Ctl,,, ."..,", ""II C3UK ..... ""''''·e btu.b we%; rq>I.><c tb:: <pnnif' ,f ""pea.

STARTER MOTOR FleIcI Coil InspectiOll I. C- for ,nsuIaoooo be\"'fta.,.,., ""'" Ihnosh ) oflh<

«>o1 _~'OI;e

!. Chctt for conunun:o bcl"'ttB bNh ends Im..t.nl 01' doe cool

l. Oed !be: pole> """.:001 fCf Up .....

STARTER ADJUSTMEJrIT AND REASSEMBlY

A CAIfI10ft kr_ i.mIJiII9. tl»t1lflg/llJ t:IntI fIW Jta<Ur ...... • =:,....,-./MGft.n ell, .,.." _nISI. StMW,.,.. .~

.; , _ life 4AIitT.,,.. ...., . .,. !rift., RfIJ

riMI __ ,. .. noe= "..-r.ratlstMt. _1rtIr,.",. til ,. tat bel

RuucmbIe !Ix .1aI1ef :wembly .n !he "" 'elK _ of diiti«mbly, mUulJ sure of .... follow>n,-

I. ,_ J/w;f. ~ play t>d~ ...... n', SeI "'" end pl.>y IIhrusI ppl II) be,w ..... 0", Lo 2 mm by _lUll, '" .dJUl.lU>, .. _ .... W CCD Ih< CCIWt tnck« IIIId "'" ~ re>r

L FiI lilt puuoa <haIi. ~ ,... .. "3$IKr and >nap

""110 tho: <OeD'" brJd4

~. :.-...: end play t.,. II>CMIIJ .... po.- .....-. '" Ito< n.aI <Iuecuaft . If II>< aod play ucu<k 05 mm. ' DI;JUk It!< nwnbor of a4JUWnI .. ~ ,noer\Cd

35

!. G'ftIJUr1 "'~Iho_lust.:eto ... <fI<IuIoJ. >ppIy PUOC II) .... fci ..... 'nl port>

L A'1nlhft >I\.>f, ,ur and raIa,o,:,,,,,,:c,,, b. All bc:innp.

to B=m, sholl w.»h.:n ;ond """" "";> II. IIC:>"'''J >kc,e.

~. Pul_

L SIidu:I ~ of k.-er

I A CAlITlIR .... - '*'" ~ IIItilf swI»u. t_ lis, Inshft, ., c~. 1IIit1f"ast'.

1. Mitt ~bly. <heel by conducu"1 a...,.kJ.o,J "' ... , .. n

_ SII.U'T EJIII'UT

Oil PRESSURE SWITCH/Oll PRESSURE

............ -\\'bm pctfomun, .. ."" ... ~. repIa:e d'>e oil pa...... WJICII aod Ibo: DIll fIr'<$!I.n KtIda

\Irk. ,...w!"" Iho: ""'!=U :oppIy a odbo od.anllO Iho lIwudcd mch be,,,, creful _ 10 ~IOIC off "'" ad hal< .. tho<

."'" 0iI ....... _ .. _"""" I - UHrU - I.I",

A WTIOI; .. ;a, • Slritd - ...... kIdt ,s-IllS, riA Jri1ts .,.,. • 1M' • ,...,~. • aritcIL IIsII tar.l*rKI s«k., a6fd11s ., ''z'''' tr.. hV .. I'm', .." IIrlUitt »4.an. p .. ,. toW .ntdt ,,;n ~.a lob .,., s.trdI blhlte..

+

36

Ol PRESSIIIf To _ the oil press>ft-1mIOO'< Iho 0.1 ~ ondof. lhc:B ,...0 . ~ ooIlftUUlt 12U~ 1ft n"' pix< Alior """"'01 up II>< <111 ..... ~ "'" til,,'" ip<C1I ::0. 1!lOO rpn :lid rue! "" ",I press'" pilI" 0iI_ JIi - 5S ..... I2.s .U~

lOW OIL PRESSURE

ENGINE ADJUSTMENTS G£HERATOR FREQUENCY ADJUSTMEJIT (HERTZ) o..c., the diesel ~ ... , """ hom pb:uI !II ~ ........ may be adJllS'll"'N'i roqwr:<! ['" <tIllfl< <peed (Hem) dun"ll the .......... bn:ai;·,n ~ { fIr>I 3lI hours)...- ahrr """ 1"'fKld- A __ >Ulu.ge adJll=>Cnl <nay also be

~ III <OOJ"""""" ,.,lh !he c:IIr-"' >peed Idjumnenl. n.... ate IlOl ~ IIdjU>ttl><l>U ",!hoy ~ 1<1 ..... _ m.aI brut·", ODd lIWlII=ln< ....

Frequeucy IS • <Iirea JeSuIt of ... ",,",~ 'I'"'='l :as Indica'...! by !he fUIaw,n., \\l>m tbo cmentor is ..... a. 1800 rpm.lMAC >'OI'"&e .... put ~ is 60 lknz.

Wbot .. tbo ~ is I'\IlI a' 1500 ....... tboAC .-oItqc outpUt Crequaocr is SO Iknz.

Th:n:forc IC chaq< .... ~'. ~. !he: <"J">< <p<cd ....... be dIa:Iced- To .. .....,ipIuI1lhc frequency change. ~""" !he fo"","".,

I. W,lli !be """"" stopped. COftI><CI. "'" At:. 0UIput Ic>d$ to

"'" AC I<rmDIaI bIoct In ~ wid! "'" At:. voIu,e """nccoons diapam specIfied r ... ~"... ~ set. and dwtF the Hertz ttftull CCIflDCC1lOll til "'" cajlKl1ar. These """'o<aKIlI5 ate ......... '" <hi: Or::t.tRATOR 5«_

""" of"'" man....t.

A WARNING: 1IIf_ stIttmg 1M ngiM"''' tIII'bIa tIut...".,-- i$ dst "..;"g,.rs! .~ ~ tn.,.u.,s awl bt:Ib.,;"g 15 ~.

~ Stan II>< CIIpK" ODd ll<lJUJID<"' ~ 10 obwn Ih< fnqurn<:y """'e$pOtwtin, '" "'" 001,. scltCled by :odju.slin, "'" $lOp bolts """ pogtiorU.,,,,,, tmInIc .... agaiN! Iheoc Slop bolts .0 eiIhet IJIC!Q5C 01 dccreasc: eo""" DO-Iood speed to adjU<l "'" Hc:m. produotd.

1. To am .. II "'" appup iau fnqurncy. ri1l'>er ItUIi"", Ito: --' of "'" ... pocI~ lOW. alaCbomelCf. Of mot\-.... !he fm!ueo<y ..,lh • mq.....:y .... Ia. !he Imo:t mnha:I bern, doe men: precise of !be ..... .

/n~~

37

FlJB. RIJI SOWIOtD Tho fud "'" """1IOid ,. m'''lnl<d In ~ !hr._ bole on "'" "",,,,"', block JUUaft of ...... bel!;wo.- the ""i'''''·. fue! 'n]C"· nOlI pump. Proceed '" foll<-> ... 'ben 'nsWhn¥ ~ .. ~...,,,, Of ..... fuel lUll oo/enood.

I . v ...... ~ 10 the [uc' ,nFC""" pump"' Cud rod IS needed. T. _ Ilu •. rrtn(IV<' the snuJl """",c..x CII''Of and Il~ JUS' bdo ... \he fuel "'JOCUO'I pimp.

2. Thr-eod the Iockn ... omo the ... I<nood Old then ~ a .,.,..1 _, of Tefton ..,aLUU 10 the thrud!; "" the .....,

l. TIread the solenoid 'Il10 Iht hole "" the ""I .... .lIId ~ the """nood plUlI",' ~ Iht C<M:t opcrun: AJlc>w the p1"""" 10 . onl.><"llhc ( ... 1 ra..-t """ mov< fully lJIIO the Inp;OOn P""'P- Do no! Ihn::od funhor .... >s 10 p<W> the plUIICCt IlIID the ooIenooci

-l. Ba::k the """_ out 1/4 • 112 of ~ rum and """"'" " 1ft

poor6go ""III "'" Io<kn-. ~ '-'- ""'" 21.1 • 35.2 HI (U - S.I .~I

S. i'rup<rly <>;>rInrtt It.. ~ .1ectnc:ol kacII from Iht """. oood. T_of Iht <:O<I1IeClI<lM plUI ,"10 !I>c en""" h:irn<'<s """ !I>c dwd JmItIds oolht cngmc bicx:k .. an adj;lOCD' _ !h!ea<Iod IIok ",nh an 8mm bolt.

6. FIn" II*: !he <:OY<:r -' ~ ond_ "'" 11>0 ...... """". =t>On lh>l!he ...... SlOpS ,,-ben Iht """"'-I "dc-cne:;ued

fin UI SOWIOIO

ENGINE ADJUSTMENTS

VAlVE a..EAIWICf ADJUSTM£JfT

.. fE: ~ IN .... tud" NM k«J Iif~" .,dJlUlutl "" • ~,_ • ...n'n . S .. TORQI.Ill"G TIlE CY1.J.>,!OER KEAO • om

A WARXING: ..." .. __ dut-. ......

...,...Is~ ......... , v.,.,., 1 .1.IIr~ ., __ ... ..,.. r..,.",,,' t ... I*ts ,. .. .,..dId,..., __ ... '., tJw nMs.

Pull 011" Ito: at brcadxt popc &om !be rod;cr _ 0fId LIIi:< otr III< ruder _ bo/I;s aad oht rodu _ 10 u.poK !he

mew ohatIlIId <raIve assembly.

~ do< po.. pIup r ..... o.acfI of _ cyIifw;Io:n 10 .......

Ib: a..a:.NJ\1O be ""y ....-t br hMd 10 ""'*'" e-:h C)' 1mdcr for YIoI"C.,j~

V"h..,. ... odjuwd .. 'IIh!he q.\uodct .. " poS1OOI be,. odPso<d • Top 0u<I ea. ... (1DC) dou ~ .....u. EKb <)', ... IS 1d,Jll$lOd folloo",,,.,,,," ... "nc', finn, order(I·}'2 rorv.'ESTElI.BEKf dne tybndtr mp .... ). \'ol~ acij II' .... bqinnina oriclo . ) liadtr'l. ROlMO Ihe cnnbhafi .... ty .., ~ die oper1ICIDft of Ihe ... _ fCif C)'bDlic: , I. Watdl f«!hI: ,nub Y!OIoc 10 open 1IIIIic.acl"11he p<I'OI> IS on . '. wah JUt>I<o (!he ",SIOfI " fIIOVlQI """' ... 1ft !be C)'Undtr~ eonw. .... 10 _ III< cnllkshlli 1Iowr,. and i0oi<. for Ibo IIIIab: valve 10 ,I0I0. Thu ,ndicaIes Ihe puICOIlI

..,.. oun.ml ii', COInJftWOOI iII'Okc (!he pu.IOfI " ,"",'II', up on tho <},Iiader ~ iDe).

Al.", \he nx:: man; oa "'" crWshafi fl'OOll pulley "'lIb die """"I ....ner on !he froIII JUt <:aIoO! _ ..m poaIc-u.. "'" . 1 I'i$IOOIIi TOC of 11'1 CCIaIpfUSIOOo stroh. ConfIrm IN!. by I'(UbmJ .... cn.nbh&ft ~Iy 10 dqIu$ btf""" ond ... 'la1hD pouo. Md Ihe r- ... oes to. d'Io'l C)'t._ ...... _-

'llU'En u ......

• .li _ 11.11\' ill =-

Adjust 1he oaI_ .. " I cy' ..... lorbodl ..... Md w...... Proceed 10 Ihe _ C)'liftdot .. Ihc fin"I onla.

~ Ibr a.bh1f1240 drpea ....... IIIImIII ..... """_"" naao ...:I ............ DUtC)'IuoXf". nMs III cbe final G'der. RIuc: Ihe cnebhafllIIIIIhcr ~ ~ aDd adJuoI It!< .... _ of me ..... cylilx;lot '" !he liMa CII"da.

Ad1"" _h ..wvc·.c~ by _III I O.oIOm ({l.2Smm) fod<r PI ... bet>o= lilt lOCka ."., UId Ibo YaM ....... Mob """ 10 IIdJ""- all vaI_ .. M ..... ell&"'" II f;Oid.

38

RNMWI the &low piliP r .... :Ift!HeJ .. ...,."".,..nd "" III< tlnm) >IId...:mblc III< rocker aI'o",.:ItId ,ad •• .' • .,.,..",. boIu. Sec: TIGHTENING TORQUE SCHEDULE.ft "" •

""""" . ENGINE COMPRESSION 0Iedt III< compreosoooI prcsan. To do tIllS .. ~ III< ... ,. .... rnDCM.' all fud "'JI'C1I.'ft- or """. pIup. drm= IOC' "'" r..rJ sIu..,tr "*-' "=- _ motalI ~ c:o:mpnsoorI ~ on the "'-'"""'" hole or ""'" pIq /10k. Coooncc:t I (on"'"o ..... IUl<:f 011111< -.iapef MIl cnonk "'" ca .... WIllI "'" wnet ......... omtoI tho: pn:ISUr<" f't:IdQ • ftIaXlm .... nJuo Rq>ut W. ~ k1rado «yImd<r_loot for ~ .. "" .... m ......... ty (ltlewlO'Jl,) ........ ~ IM> ....... ~ 01"'" om.n. Coo,.. 0 prcsan ohouId ... doll",. by """'" _ 35.3 pEl (U qIcm') "' 2SO rpm. _ , ..- "._.z-._!lU "'~

If. -.01< ""Imdct ~ Lbak<:d by huI1by cyloader. "'" ".""""mm IS ~"""" .-ai .... Of """'" .-.booocL OIOCk "'" ..- d.>ntICeS for "'" weal< cylinder. adJIISl,.. ~ and _ ., .... If''''' cy1,fIdcr ~ IliIl low. apply • small.....,., .... 01 oil 0Il10 !he cy\JfIdcr 10 oeaItho: no,' _ r-<p<a !he InL If """"IftUOOI """"'" lOp • tho: rmp .-.: fauky_ Abr>ormaIly hi", .-...cIOftp on all cylmdon oldocljos ht;ovy eartoon """""",1aboM. • """"""'" dIM m'aN be occompaoO<>i by high ~ and _

110ft: I" CtlU of"""lI' ..-b",,,,,,,, tJ10d dno<oat, ... ...,...~. llot aao<.K ""'" k flul Uo~""," p~.<f FUEl. INJEC· TORS. Pbor foe! qwWry. .~~. tJ10d IQu of po<m~ /WI pll'SSV"e ID W ~ pomop .. -.II ,.....u ... i"i<wc" -

co· P \ W. TUTDI

__ -- -.uTOII 011

aow PlUG IIOU

ALTERNATOR TESTING

DESCftIPTlON MOTE; 1M lOKII' BCD ""'_ IS tID( ~'I"'PfHtI ... uI! ""

"""""""" 0-,,,,, .. UI«~ by" btm~"1~" _ II ... wqruJ pan of w J OK ... ,., .... _

The chirp. JyHrnI_ 01 ... a11efTWOr ..,11> ~ ~ rqublar . .......... DC "'mal bInIeI.I. ~ mounIld oc .. -CUll t.u\cr and • bmo:fy ...... COIIIOCCtIIIJ QbIes Beca.se ol ........ oI",1epWd ',"",IG (lC"f) m. eloc,"""" ouIQp: ""ubocr II ->' iXIii4*!' and .. InCI w<d ... ....wly or .. .... t.tof .................

""' .. TlI(uu f SHOOTIfG

A WARJIINC: A ~1Ift MrIfUl. t.WI b«-. ,.,

..,. "."" 1.-dI.mII 1M .tt .... 11# CMJIft"~,,,

Thn 1nIolbIahoau ... seroomol' or ..,It! .... ~. 1111 IS dl:\l=Hnod """ "'" .oIccmaor or volute "'1"1aior II W 01 IS

btOIlO ""'" • o;r.oahIiod I<dwta:aa c:hc<:k 01 eM.

The al&aura dwJu'Ia amII\ chqes .... $WUJIC boIIory and W ~ bonery. AlIISCUIor..,1h • diooX. • y«ecw!

or .. t.acry IdcaoI J'l'-1Id:I1$ .....ally ..-.led III die"""" 10 idaor dot bakiltS to .... wn'K<' ~ 11_ disd .. ,..t ........ IN ......... boaery If Iiho at.:eo »= IS "'-J:IDI .... ...,... '-"Y bullIOt tho ......-.ce ....,. . .... po(~ .. ", .... "" ...-. boaor>t cNrpIIJ ~ INlIIOI WIllI !he *'-. A WAfUOIIG: .., .. 1tMtifIt *' ."... alb tII1aiI /lUI •• =;_ if dat 1II...,,.u! • ., .." ",. , .a ,. AItItr .,.., !at ~ClI.1S.

A WARNING: *lriU1ts. _IJC Cin:tIits: lit: MWI.Ie ~ .. ,tftlfl --"9 11M ;,, __ 0' &1fHMs. AhnP *'~ .,. ,.wr-*.

iIIIbb DC aA& '.,IIt-. .. ., .... JIIUI_S ""-,.,,.,.;z,g DC mtbIf . .. .Ie td$ $1»111"" ... 1fiI1HIIIt".,., tN . .... ., At: diu//;$..

39

Tesliog tile Alternator I. Sutt tht E.q __

!. Aficr a few "' ....... 01 ......... ' ~ .... ;<¥Un, hoi· Ia')' ~ :II .... boua}' '<m>1JUIs ""'" ~ 1IIIIl1l-mc\< •

.... ""OC ........ The """'" IhouId be lIICftaSInlllJ'oQd I~ ""'" If d .... lIooal • ....,,_ ;..~ T .... 'os..p ~

~-J. If !he wrtiDi banery .u/t;IJc ",maltlS.ound 12 WIll>

after .... cnJIn< II <Uncd WId run (Of I few """",U • • problem owl> ...,11> Ihe aIIenuIor or .... cII.v''''I ~,n:u"

a. Tum 011" .... en" .... Impea all "'In",:and eOft_' ...... Ensur< lila! lilt banal' ICm\lnals _ the ~n.'..e pound connectooBJ on: uJbI ..... <kat\.

ACAIlTlON: To rm. ..... t.,. "'"..., cbtJiI!f dtatII, _ JIIttt ." U. ..,;.Iutf..., $Irikt ... fIW ~ II rntJItIf!

10. If a ~ oekc1cr ~ " .. the doarJmI amoo~ =_ ~ ".,.lhro:onm-... ~ T"", <mthe rpwoo. ... lId>, ..... da _ run the en,,, ..

Ii. Orr:d Ibe ~ ~ If r- boar:ty II '" JOOd credU_1be rudiJrl JbluIr:I b<c L110 L) .....

Al.TERNATOR TESTING eo Nowchr<t Ih< ~p: be,ween Ihc ~1UfIUI

oenn,fI.>! ,B.) ~ gn>mId If dIo (Uan' IS JOOd. Iho od"lC ...... aIIcmaIor should Ix cbo ...... as Ihc bao-1Cr)'. or If .. """"'" II III .... amat Ih< _ ..... .,.. .. -.11100....0. If ...... ~ "'It' ... UJRS 11> ... <_ bel_ .... IIICt1>3la' RlIho '*'"'Y. ~ all .... ~ • IDol< for "" opcn!IOJ '" Ii>< <h:Irpft' or· 'W,

"""" ". ...... l Stan Ih<...".. ..... a..ct!he....,.. ~ do< ~ pPI. ODd pU\I<Id. Tho ..... rudin, for • pn;IIItI1y operata", a1\etf1MlV IhouId be ~ 13.$""" l~ ¥OIu.. H )'CIUf al-. lOr .. 0-. or 1IDdcr-darpaa."""'. rqartd >I. rdabIo .....- sIq>.

IIITt: &fDIt _~ •• -"" ~~ ... " """-_ '" .... "'" diGr 12 ...a. DC ~ IS

P,,"UN'" riot £XC 1~...unDJ if riot p~ WI ~J CMI}' .try ~ AI 1M B DUlp<JI .. ........,L If 11 >OOlIJ ...... _ ptrUNor. £XC .,,,,.,.. ,roc • .... ""' ....... /<Nbmobtllld~a/ftI .. (. ,

40

Alternator is Working 4. O>ect!he 0011.:1,. 0I1h< ~ ~Ilcry TIm hulCf)

should h:I .. ~ .... brroottn iJ >nd IJ II'llIts ",1IdI1hc ...._ IS".", ..... U ...... do<R ... poobi<III '" tho ..... -o:c t-tay durJuI. o;JmRl. T"",· ' '1lOI1hc on>-.a: I>:IIICf) cNrJuIl am/J' by cI><d:.n,lhc ......... and <~.

the soknood.lSObIor. bouay ''"''''''"'''' Ihc bxIer) ,~l(

A CAUTTOlI: __ ,..; .... ustJ.I1Ie./tmvI1t + M emit II MIt ... 1IigII ~ t6$t'" (i. ft. ..."..,. r.un --'IN"~Ii~.

ALTERNATOR IISPEcnON \\'hen rdMktia,lhc etlllfIe.. Tho ill ........ should Ix cluncd and ~ Tho housuio, an be ""'P"I off .... 1I> . ....... ... """ Iho allenlalor !.mllna! S\l.Id$ should Ix cleaned ... ,111 • """' btu$II. Mat< cctWtI Ihoo< ""-'<h '" up<- AI"" cle3n tho .... ma' __ thai 00IlIICCI1O \be .... "'a' horn<u..

T .... !he"'" poilley by "-"1 II <hoodd hn SIDII<IIhIy

~I 0<1 w.tw:n !he aIIcfuIo< ... 1asI ..... ..ced. Ihc bnIshes .... y ....., r<PI"""'I- U !he aI!cmaU1t .... all iUOpCCL ",tid " 10 l.........ce ohop for IC<lln, and ovahoul

• •.• , ii&1"'!'

7 .6KW GENERATOR WIRING DIAGRAM #1139284

.. ,.'" ... ·r=fl=:;Ht-"'"------.j ... ~ ---

, , : J

.-rEl:Aa ... -q1noo:d1 : sIoJIt lot w=JW II< ~ I _.10m .... ad. :J

_tn-Iv~'" • • .. q MII"",--, Iv """" T-M ....... ..,...."...,. .",....., "-1IJO ... JOO ... ~a-...,.A ..... """' ................ '-'I 11(1" _pus 12 I1lC toiII--a, __ "'" ~ bo<t. $>olidt I .... _Iot...t'" , ... - .. -.-. '-=." ..... ;;;-~""'" ."..u- iJw __ arcuu.

," - " -" - "-"-"-' : -- --- j

i,,·O·,·.I , -..0"","=" .. _0 ••• '---- '7'_-- __

.........

=

----

l .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _ .. _

11 V~

" , • • ··1 .. • : n"'_ C

~ 'It _

'el " _" C ,10"".'

" I [":'nO( , , ' 110<'

'- ' '_"c_

7.6KW GENERATOR WIRING SCHEMATIC #039284

I r.O' ! . .ou "" , ~ .. - -., •

, , , I s-, .. "

M

.. ,-, .. -- -.' I ~~_'\Ol' I $> .. {OO' ~ r - -' ,

'u u u , , , , --_. ' I ,,"" .100

~ " .... ,./ IT'" , e. tC v,T ' " '<~ ;',

...... [0 - -- " .. f '-.-' -} ~

0. ' u ... • "'-1 "". ,

• r ~"I' ~t ' .OI~ •• r:>-t , ' .. ,,,. • C ' to, ·. ",.,

" , ••

p

~- .. ",', --

II""" " ., •• r(l I I " "" _.u, ~g" $' ''' " n IT'" 'e::; , ..... "'.,. ~ . - _. <-••

~ - '-,;.;' <11 ,_ , 'J " ITC. , '. , , • .. ,., .. ,., ",., .. ,."

r -t------:- --:------:---··- ·· -·--- ·~··.--··-:- · ·l

'1: ' ""u 1"1 • I ' ..... !.'!.T~. " n"" ..

1 -

- ' ... '- - -----------------~;--.-------- -- .. - - ---- .. ~

42

, • 0

I ~'lt I

.-n: ;}Jt.l1It-C/J .... udr w.J4 "" tIIJJIllJd ill rJao araou 11>. ..". IIw Star1<7 fr- 1M btu:#ry '" .... ....., ... ..,.1UId ..nao 1ra>u,* .... T~ d&.l...,w =ntn ~_]IJO ... JOO ... .....,.~" ~-.~.-.-,afl71a.psm 12 \IlIC ....J1-o,_ .. J-ai<-. boolll JWIIdt __ «-.t ",

--.t.-" IN _.:UCViL

5.0KW GENERATOR WIRING DIAGRAM #038124

I I Ir-i , , >- I ,

1 r '-:-11

.. .. -.

-

1\ ' ,- ' <>..c. I .. . L ' I . • PI .. - .. I , @~' .~ 1- ,

- . ' C; ... 0 ~ ....... , L __ ____ ___________ ~

43

5.0KW GENERATOR WIRING SCHEMATIC #038124

., . ; :.,..,. .. . ,

T -~-L

I

I.,.".,

II ~ .' I . -.. . .

REMOTE STARTISTOP PANEl

44

1

GENERATOR INFORMATION USE OF B..ECTlUC MO IIMS Tho po<I'o'a mJI'IfUI lei Am .. dean.:: .....,. II ~ _ !bill IS rcquutd ... k<:q> ~ ........., JIvr • IS IoWICd.

s..........., ~ murda ""'"' ~ 10 sun Ihem!han odIon. SpbI-phMc (AC) ID<IICn rtqIIIR ""'"' aIrTmI. 10 ~ .... SlmlIIr ~ m... """'" 1)'ptS. n..,. "" COM

.-Iy IIl«I on _y''''''''''''' Ioods. $lid! "' "'-...huIa ~ or "heRe loads .... :opplied :Uiet ~ lIIOI« IS

~ sud! as >mill "...... toob.. s..:.- !bey lUlU .... S 10 1 1UneS .. much ~ 10 sun as 10 NIl.Ihnt u ... 5hooIId be &YOOIkd. whr ... _ powblo. If rho "kctnt; _ IS 10 be dn· .... 11)" small I<nenIOr. ~itrr oDd ~·,nclu.::11001 mowrt r<qull'l: from 2 10 4 u..... .. nwth <Um1I' 10 sun as '" 111ft. Tho turTeIII rcqu.rcd '" sun any """"" """" .... tII Ihr food conneatd 10 II. All eIear>c """'" OM H 110 ... W

DIIIIIpI'QSOf. for .......... ...;0 ~ men ~ INa • _ 10 ... hod! "" laC II • t

'1IJ'1l; I~ dw ...... I<>I>k dw.......u......AmpJ for SwtJ"I IS

_for _ 1mlJ/l-.. -forlarJ"'_J. 1M...,..., P, IIus IS ~ 1M IwvrSut _, typo IspIit-;NuJ"'" .... ........ ~,s.:;u..

BetauM: dot huYy .... 01. """"'" D<Cdod lor NtUnJ _ IS rcquutd far only .. __ "'" .... _ ... 111_

b< be V if • con bn", cho ...... "" III opecd In a r .... ......so. II diII'oaIIIy II u.paieDCbd ......... -. UII olf 0/1 odo!r doc1n<:oIlooQ; -. if ~ ..... c die IoC .. ..... Icanc_.

ReqlIred Opeming Speed ,... Iht ~ I'Int ";11> .. Jood "!'PIa. Ihen • half "'" ~. apE!ly. Iftd fuWIy Iooded 10 .. fun capac;!)''' ondiaed .. W .............. data plait.. Tho \lUIfIUI voIlIJC I/ICIIIId be ~t.d ~y 10 .,......, pOp<r ope,*,- 01. .... ,.,......n. plano _rho oppI,-,- ~ itWia. If ... 1£ "*"- or ""'pae meta II no! inoDJlrd '" _lOr ..... and ~ dIoc:t • ""III • poNbIc _ -' ""'" prabe.

IIITI: 1i1w" IN wJMi ..... ~ IN ,.....I'm« iJ itulQ/ld c-..u AC ~ of flO....as oorl)< ii ... _ ... W' H dw1fw '-_"J AC "nrWra/ hied "" --nvN It> fI"D..do _llO*AC "'" Iqfor dw _'I~ ptad. n.u .. ill .......... rood __ , taprJAU ft- IN

.--

45

Generator Frequency Adjustmtllt Fiequao::, II adirea ~kol "",,_......-. opud.. ..

'nd.....-1 by Ih< 1"01""""',' • ·Aiben .... ~ II run .. 1800 RPM. Ihr/£""'r<

0UIpll r..q. "'Y II 60 Hem.

• "'bolo rh< ~ II run 01 1500 ~L ""'At: ~ auIpUI f~ IS ~ Hau.

1b=f<Jl'/:.. 10 chanl< "'" ,.....aoor·J f~. "'" cm=n"",., dn"" C"II ... ·• speed mllSC be dwlled. A ......,6"""""" of "'" AC output ccnntCUOIIS .. ,"" .......... " :abo DOC£>..., Geoerator Maintenance • MamWfllll.I 1"'"O"3tlW do:WlIIoeJIlf ~ c..:-..:_" 0( ImIIJNI t.o..Is IOId ftCuII= ilia)'

bcc:cmr .... 'odtd.lOId """Iaboot 1Wf ..... "'"Y ...... IXJI>.

doIatal of aIts. """- eftJI'I" w..... eon-. .... .... aoo...:! 110 b.HJd up.CIoaaI_ilM_ .,........, .... y CIUX a=stYe '-I attd reduotd .... at WUI:linI$-

• Far ,."' .. u}' ~ coodi_ .. Ihtn ..... -IIIiIiIttuq: ~ DDIItftp. shoWd be scn,...tor_ ...... 0II....na:s 10 ~ NSWII -'_ Typool ......... sugtSWI.... Oaubm a...-..I Co. "r-ro.Rust; AC..oI 10" attd Ashlo<td "Teet)"k niH or .,,,"_IIL

• In:tdditioa 10 periodic: elull", .. "'" ,.......cr $lIQuid be Inspected for (a) hJlllft<$l; of all «tnnecl>Cal. (hI e-..xra oI...ma.tcd ICmIUIah IOId (e) IoaoJc or damapi .. 1ttt.

• "Tho """'" discs OIl lin'" be.,nl ~ ohauld be chiochd p<:nedic.al:y it' poIoSlbk for hpu.c.. of KI" ....

...,. for any c.iducx oIl11CtpeM oncbft& t..k=. o..c.

.ohouId. ." be allctwod 110 bcoom< NIoI)' be<:outc "'" .... y

...::cIa ... cnd:lnJ. Tho boIJJ I*fIdt &.st the '*- disc 110 "'" JeD=lDr sbaft _ be Iwde....:Illftl SA.E ..,0. .. ocbttd'otd ~ 6 radi.d !NIb. OIIC • ad! 01 dtc 6 0Dr

acrs 01* bioaod-

• The ...... If1tIaCUr< ~ " hb I -.I Kded. .. mri='= « If ~ H __ . ,f ..... batmJ ba:a, .... -r or ~ .... bot"" II rq>boal

• E.umiae bearmJ • ponodic .....",.. f'io" mo.""", ... of WIi shoWd be 1 ted ......... forc:>o II "!'Plied. If We IDCIlIOfI II <kIectabk, bc:¥1np .... "'Un", or _ ... OIl WIi of beanDI oocke\ ouwdo bear" ........ CICCWnd. Rrpair ""'" be malo 'lllIekly or ""'jOt COIIIjXln<nlJ "'111 NIt and auoc .... JOt <bmal< 10 1<.....0< •

7.6KW 8T GENERATOR SINGLE PHASE DESCRIPTION n.:. gtn<ralllf II a iaur-poIe, bnnIIIc«.. .df-uc,wI renc:r.llOt .,lIICh ~ oaIr IhI: <In'-"'I (~ of Ih< CDpn<: to pro. duce AC 0IIIpUl. Tbe copper >nd bn\,rwed IfOII la !he ncHe. ~ .,., =POn"lbic fa" "'" self-c>.Qun, fUUtt or Ilus ren"""Of_ n.. .... gneuc: 6dd produocd """"'" on AC ""I<age IQ

be Induced ,nto the .. ~ """Ief ",..,.. .... indi .. ,. dIm"g I'tU""".ThodE< Iocar.:d In .... ~ mtar rccufy ttu. ....ttage 10

OC and wppIy .. '" II><. ....,..n.,p of !he IOlaIlag foeld. n... cre2IC:Ianelcc1romapcuc tield ... tuct.",... w..ug:/> ..... .. ,odmSS 0( III< !IWtI suter. mduc:ift .... AC voIta£e "tuch is .. ppliulro • Io.ao:L A "<;> -.. rnruf .......... IS conDCClCd in par.>I\c1 II) !he AC <IIZpI>1 oC tho m..uD >UlIIt. /UI AC >Oh:agc .. ;woduc:..:I ,.0 !he au.iliary wUldinp of the InnSfom>ef and tho "'"''' ..... or;wl,., '" wm. supphcd 10. ful~ ......... bnd,. =. Ilhu. Tho =:tifin fI"O'IIo= • DC ......,. ,.0 funher = <he .... olel 5UIa" ...u.tinp. on>bIinllhe I"...nt(l< '" prOduct: • raocd AC ooKpla.

""""' - '" lZ m.a IT WEllATfIl

Circuit 8reaker A clmlj, ~ t$ ,RSUlled on ~11 V.'ESTERBEKE relIeDun. Tht5 Clmu' bouker .... III 3U1Dm.Ul<;,Ily d«<;onnccI ,;<n<T

...,.. ~ III esc of all clcc1nc:lI ~. The C\mII'

breaker c:m be manually shu! off wlH:n """'1CtnI' "'" lene",KIf '" ~ 110 AC 1"""'''' .. C(JmUI~ &om Ih< I""''''''''' 10 the~l.

1IlfE: Thu curl,.uh ... a>"t:IJIabI. ,., Q ""£ST£RBEX£ ..,Jd..", LIp ~,IItDtkII~If)h()tlJ. ~(IftJ/JC'}OI<' 1f>'ES1VU1£K£ d=kr.

;- --~.- " . " A r-------------~

: . EilJB : • I

~1 :1* 43: I , I , , L _ _ ___________ l

/L EXcrITR STATO R WINDING A· 1 E.>.ciu:r SUl(r .... ,ndlftp

II. EXCITER ROTOR and F'IEUl I . ....wli>lry Wmdinp (A. B· C) 2. Diodes (6) l. R<Iu<I., Field II'!l>dinp "- Po:ti R ........

C. MAIN STATOR I. ~w. SUl(r WindinV 2. Mom Slatof ",iDdinp l. M"", Staor AuillZ)' Wondinp

G

, I I I I I I I I I

• • , , • , • g , L ______ J

® 1

D. COMPOUND TRANSFORMER I. Compouftd T ...... f""""" W""hnp l. ~ Tnn<f<>rm<r W!Jldjnp 1. Compound Tf2ZISf,,",,"," ""ul;" WmeI"',.

" •

Re!><WICC ~np m.:I YOI~ checks ..... be acceucd ~Iy f<)< "'" """....,... ..... in "'" uc= .IrCUI'''. G. C·3 ~ 0-3 by ~ tho c:okw codod WIres. tho_""" P"""S u-"" tho ~ ....... I!\.XJC. """!lett ."ed:'ft, ..-mel ... , !"CSIOWICC n1 .... be ....., to 11ft bod! of .... CtlmpOfIOnl" S dcctnal c.atlncctJOM

G. BRIDGE R£Cl1f1ER

I~J WfSliRBEKE r~_.&_ .. , ....

46

7.6KW BT GENERATOR TROUBLESHOOTING The foI~ ~ch.1n" <bIpood 101M , .... po. 'fIIO p'obIomo .. hod> m>y be rae-..! .... 1II1ho BT bMtIIcss ~ opcnun, DOl ccmpcuod u.sfomoa rq. "'-. Owoaa 10" umpIoary 0( lIMe <qI I v« -.:I ..... ... ~ .. ~l2tNdy QS}'. CIa !he rdIuonsIvp beI""«II _ lad effect .. ...u.n.oc.t Moll poo<MIaI prot>. Iems .. to"oaOd In die Ial of !has "*, ""-'u """'lei 1ft _ or .......... be fOUD<!. _.....wd IJUlIy ~ your-.f) ..... d .. Keep In ""lid lhaI • bux fund.vnenW ~Icd .. oIekctnc· ny " requored «:r tI ... !I'Co1b1e1hooung. ...:I 1I'"J'1 ......... t lhaIletNJ ooItapS .. J'I"<_ In "'" ~I"""uy. Ihen:'ore. nlrmlC ,_ .. eu<nuaI . -tom 1roUbIeohoou"l ........ w.

47

Only a _ ~ 1<IOb ... ~ for ~ ""'" n:pw n....c ... h2ad IOOb . .., amp prob< _ ~ ~ ... ......". ....... capoIIIo of readJa, .... .two .... ohm due 10 "'" 11=" '- ""!U'f<d m 1Udln, ""' ...... 81 WJ."hnl faI.....ao

Be,,,,,, ~al 3/1)' rqwn.. '" a clar :on e'p""""'" DI Lht po t: Q as J>05SIl*. ptefenbly from:lft oad:>'>cIaoaI....n. ......... !he .. " m. 1ft """'" C2WS, dII$ may bn'110 hchl a pubkm . -Iud> IS ",LKCd 10'" rnntood ofopnKlC"l ~ 1Iun <qUIP"'"'" f .. 1t. Bnn, bawc: ~ IOOIs ..... ,.,., en Ih< INuallnJl10 Iho: pobIem cqulpmcnL ouch u: diodoes ""'" _ •• r..:ufla. on !hoi If the ",obIem $I>ould be found In """ oIlheK 020i1y repI.ocabIe pNU. \lie problem ~ be "",I<_ died =ly IIId d!ic>elllly

.D-3_

- -

7.6KW BT GENERATOR SINGLE PHASE IIO-LIWJ VIl.TAGE ADJUSTMENT I. """'""'~ II .... .....tI1he: .-.- rqu.boon

be"" ...... atd b\' file compouod 1nIIif ........ l. Opera: lilt ........... oppIy a 1I'OOdo!,.Ioa.:I ___ •

iIr and '-.. NOlO !he vca.,. 0UIpUC '""" Iho p..... ·'l20u ..... S) rJO ... 5Ohcnz). The-ad ....,. Iobau/d bc bctwua 12 1 . 11" . II 1St" . 62 11m! (2).C - :nil >0lIl. " .,. S2 bora).

IIJIf; 1M _'-I....a.p JIootJd bt- tIdjasud .. IN voir_ .".. pootlwed "' .. ~ __ ~ $~,.,J. _ _.,.'-1 IIIt1tJI H ~ III _ tAl ....... · p.u <IItd .... ........ n tJw....,.. ptO<J.ud by'" ~_~, ... .--....yIt!o4 .. , ...... 14 <1 _ ... ,-..

1. To ..... 1oooa Iho:..,.... ........ ol.1f}'l.' Wc:bIcso (~.........J) JftpUood .... _1>Cd "-. Iho ..... ....:1 ~ 0fI .. ollho: oompot.md .....ron.-. Tho IM'<NI used ror lIlIniINa, should ..,. JOf\eIIII "''' .... -..es en file 176' F (IO" C) nnl"-A IIIIIIIlItdlltbao .. 1l<i-ioi4 ~ 11 to 3 ook5) <;an

~ tit w 'opItShcd b)' cc1IlI)r llppmllho lOp of Ihe IlmlnaICd lied bor III rtducc !he lIP berwutllhe .......... $horns -..I tho ....."fOl'll'lOl' COf*.

lieauatll' F1eq1et1ty

L I'roqtIrDcy iI; • di!m result of ~~ spad: 1800 rpm • 60 hmz; IXXl rpa • 30 henL

::. To that< JCII"'IIOr ffeqLIency follow tho SIepl bcloooo L CoNi ..... It..,u; _naI bIodt for !he desuaI "!II,.,. &eq......,.. u.o..n below. EMI.n: INlIho US<

pooaod ~ .. CIOIInCCICd 10 Ihe DDmCIIenNIlaI bkrl ---lOT£: nw~,,",,,-.J,,,,,,,,,,,, h ~~ ... ....... iR==Ur .. < .. IN .. wAC CIInIU.\as II upatrJU

",woIONI f"I'W'd"~ TIMI...JJ ~ ... IUUl po. "-I.,-..I_ ..... ....m

10. SUn !he e..-, _lOr ....u,. and ... eftIl ... 100-

Iood 'I"'"'l AdJIISI dot d¥oIde ...... lilt IhrocIk SlOp JCn:* lID proob::o: ..,... spooed d<:sued. 6Ot..= ~S!*'i "-' - 6l.0hau. 50 ho<!z ~ speed.. 51.5 · 520 hom.

1IIf ___ _

111 __ "_'15 __ ' _ _ ~_.ZJ)_ IO~_-, _ __ ... IIC_ -.---..... __ ... .... _=11-___ N_

--~ 0 .. , • '='

. "

c.. Alia LIx _I00<iJlllolmOnl II mock. !he ...:Hood ~ .... y ....... 10 1M: .....:IJU>II'd- la ..... n<n, ,I dot Je1IU3ICII" ..... procIu<tnl dIt (()rJ..:l ..:.-Io:od """~,.. .. II>< I"""JC'UJ ~ KIlIn" n wOIIId 100 (()rJ..:l .. till< ch3nFl hem ICWD" ItlIhe ..- • -. od~ ;odJOlll II'Ic ............ k· IIICSS IltId.r !he -.....:I ~I bor of Il1o ~ 6Ohom; ~~ 121· 124 ___ SO hom; -.loa! ~ 2j.I.. n ..... .

L load ""'~ lOw ....., a'IJXI . ....... C<lfft·

opondia& 10 dIt hom. speed oI lhc ~_ .... ,......,-60 benz: Jmded speed. SS-S • n 0 boru SO benz: Ioadod speed. 4' • 49.0 hM:r. Muomum ...... '*"'P aa:r;:ubk .. full"""'" 0UlpUI , ..... , 60 hom; 1011 · 110....m SO benz: 21 S-- 220 .... Should !he ~I" drop 100 ...... !hi: fIKIJXI' ... Ioa6rd e1C1IaDOn cao to: ~ 10 raow lhos voJlare by I<p<:»&iJUUnI!ho: c:oiIiICCUOn .... !be \toluol" ec.ou..a.o.. T ..... iMl.

I' SAl. aGel -...; CClN:I:I1IIIIIS ....... r .- _loOllU.n."'- ......... fo I

J 2 1 1 J I ~--! ot:lOOW l-...J @ .,x; ~~ _

• -{'W"......!d¢GGd(i~-1<IV'F Ll 1111'1MIII

I $ ~. I 11

L! ~.!.t=~0WIXl~~ • 2lI'ISlII I

~ WlMt)L-.!WSi.i~ Ll

'S " . ,.

J ~ 11 J. _"W'-!tw:ai l..-! ............ ~_

J'mJcw:ml-...JEUWi' I ~ 'lIS ••• If

:"'t2n,t ,tu:iWJ ~....!....'tI'J'..! I

lMIG III

, , . , --".""~"'''''-._~_or __ . ---......... _ .. _-... _- b±d=' 1II=. b±d:

48

7.6KW BT GENERATOR SINGLE PHASE IIfnRIW. _ f ill

12 SM IT IiElIEIIAllIR

r- - -----, , C '

r - - - - - --, , 0 ' " 1 , ,

i ~ 1: t ~ i!

r - - - - - - - - - - - - - ~

, B ' : r----'-f=r-,-J i ' ... i

i '... i

• , , ~ , , ,

• , , , , •

• , • , : t.._-'-L ,

L _ ______ ____ _

G

: ~' .. -.I-_f', L -- - ---J !i

== , 1 3 IWKl/Uk

L*1-1--I---' I __ TlGJI£ ... •

• o , ,

® , OUKG£

GRUI! nuow

REstOOAL VOLTAGE a.:CI I. ~~l!·:n.oo.AC.

tmTE:: n.., """""" of IfD-Ibtid voiJD.r. protJ..cd by 1M

Z-""'" c"'" ~ "" ~'of """',. '" 1M IU"'''''''' rM~lmayliL

Th. wItqc is tho: AC oQ/tog<: puduca;I try Ih< ~ from map<USm in tho: DOlle>" >WO< t\eld. "This vom,. is ..........d beI<> ... n Ihc AC I>eUIRl md boot Ieg(S) w"b ..... load 01\ tho: ,.II<nIOf "U"''''I :. ,IS benz.

~ pcocD<% 01 rtS>C!ual -..1111< IS "" JJ>dicl>on WIllie follooo .... ,,.~ .................. ~ OK.:

I. ExaoetRator(B-la.b . .t.c) & (B.2) Z. R<Jwin. Field (B.3) 1. ),I.,. Sta/J)r (C.\ '" C·2) .f. Compound TrwISfunnu (D-1 I< 0-2)

11>< fa.]. lies .. ...., Of men: 01 "'" foliowul, compo. aents .. II'>< =itcr CDCuIt;

A. E..aw SaIgr (A_ 1)

B. Sndle Recalia (G) C. ~hl1I StaICf AlIliliaty 1II."lftIbllp (C·)) D. C(lmpl)Und Tr2D<f..,."". Aw.i1Wy wmdi., (D-J)

1. Tv.elve (lZI volt> OC aci_ 01 tho: ~;u;; .. , SIawr

w.ndIfIp slnIld cauoc tho: ,.DCnICIf 10 pr<XIuce bet-= In· 115 vo/u AC between CKh ""'lead and tho: bOu_ nl (T,.d"" voIu IX: IS appI><d beI ... a:n tho: ~ftrd (. ) and H 100& 01 the bnd", =tIfie>' •• to .. :and - 10 - .J Cam:! >'OIta,. produced with ,_I"" veilS DC t1CnatIOfI

........... Ihc fa.It .. III """ Of MIn altho: ....... Liwd "",""'., .... B. D 0< E.. If tho: ~ doEs I>(It ~ lZS· IlS Y<>Iu At:.. ""'. IlICIWo A and C.

3. ",. 1bseftce of any YOILoee from !he F""'"Ior Indic3Ic:s a faull",",,1he mam<wor~pC·! andC·2_ Ihe compound lnIIOformer wudings 0- I and 0-2. OIl...Wkd componems !hoi QtI produce II"s ........ ...,.YOI\age 0UIpI.0 ... Ihe pos.·tcSISOOt 1ft Ihe «e,"", I'CICCIf aftC! r ..... or """" failed diode> 1m Ih< e, ',1C moor.

49

, , 1 g

"- Apply! 2 .oi. OC eunauon 10 Ihe eu:;,u _or ",,,><1. InP as e.tpL1tned In ~ 1. A fault I~ the matft

$U!llr and/or compound ~ ..-...;!in" sw;:h ....

short will ~ the ee.mentor ... " .... 10 Io>d """'" .. Id the >honed Wlndlnes 10 o-venntalIy prcd!rc <mOL: '" the ac,Wl(Wl .. CDfIbnuoai

4. VoiI2f<.,...,..' ~ IIwI ~ and Ieos <han tile r3Ied outpullndiales a fault In Ihe «e ..... """",",lei B_1 . 8.2. B·3. Exc,1ObOll of !he rena- as uphtDed In pa-agraph 2 sho-.rlrl prnduoc a p>n:.>l rue 1~..,:Iure """. PIlI and..m..r. removed. the ""'"'ee "'ill re.um 10 !he oript>allow oulpJI.

Ubi .. T1'E c;aEJLUOR

WIT1I12 \'Oln 4U1IIf m;:mfl c.rwrr t'OUIIITr ctJRRErT: "' •• uo_ « -.. .. _c-.

MOTE: Cw""", >nOtkl lmdg. "crifi"" arr cmrfigg"d dj~,.",1y. "", .. <IN!. a'l!

snU l«a1.d at rl< • • t>""~

7.6KW BT GENERATOR SINGLE PHASE BRIDGE RECnFlER n.: -t< """,ficr Ii WppIord At: .uu,. fiom dx aw.olury Wo'lDdmp III !he "" ... _ IilMQ' (ell .nd "'" compound nnsfonncr (D.-l). """'At: "OIuI< rne&S<Itl!ttt SUIOr 10 UIducc & 1"<:Id _&I> ..t.o:h dx UCWf mer ~_. The OC .." .. -.-.n:d .,.... dx ( 'O) .... (-) ........... oL ..... _,. ...:uher dunDI ....... ~ IS .. follows:

!.liD \..... 121)oUO NJL F/l... NA..FII...

S-I' ... ...c a-lhollJAC hi'- 01 !he bndJc IlCUm will ruult III • __ field ),."., producaI by dx I!:lIc.r $UIOf ""ndi.p.. A __ licld os pre_ $<1Il. ..., 10 dx mapcustII WI dx u ellcr _ .... ixb win cadt !he ~ 10 prodI.oc:c mIduII ¥ON&c---

50

TestiDg Tbe Bridge Rectifier for Fa.tts W"rtlI Aa Ohmmeter (MOl£< __ s....p- lIIO)

I. Set III< ~ scM: on RX I r ~ OC) W OCIW _.= :!. C 'dx po5IlM ( .. 11o.>d hum dx .............. OOf'OOm

-.; ToItaIJ: dx obrrmc .... I ~ (- llnd. -..eaQr. ..,. CCIftlaapomn '1 . ~.J. ODd ~ Tho ohmme .... should ~ "'" <kllet~ f ... :>DY "'!he pootMJ

""""" J. ~ IIrpculrVlO ( .. ) lad frum """" ~ _ o:ortI>e(t

!he ~ (-) lad 10 paull N _ .. 1111 !he poSIll>C ( ~ I

Ie.Id. "" .uy I<lUdI pra..u ' 1. '2. -.I Oil The oM>........ ', -.110 sbauIcI ddIecI wtIetI each """"1$ _hod. "-'III _ ,..... 01 ....... ....... """"en w <ioocIn III .. """'"

... Lcavia&!be """"'" (.J ohrnm<t<r lad on po:.~1 N . I<lUdI poioII ~ ..w. It>< pooIl/VI! H lad. No ddlom"" of dx ....".jJe ..... Id oo:ur.

5. "- dx p<Jo.it:vc ('OJ lad fll dx <IiI<r>mt1er .... peIIn, ' 1 IIId dx nepI/"e H lead "" pooM . J no.~. should .... ~ r.ry drlltthon of dx ",.,..jle (110 dtJkcnor, ~..nn. .. ~). Rcv=o ~ COII~ and lilt ahrr>moa<. """'Id a&"'n ~J''''''' 110 dtl'lrcbw Jf lh< r=ifi." l.iI. OR)' 0(110: Jft" ...... 1aIS II ..j ) " '" drl ........ ud....,..1d be~.

IIITE: ();jJ~mJI Sl}kIrnodel_, ... -:l p<OtiJtn QPPOJU' ~ f1- do.! aIit>w It ...

7.6KW BT GENERATOR SINGLE PHASE

EXCITER RDTORIFIElD ~ _ " C'-P "'. b.-l ~. t..oc- the IlItu ,orm!ll.al 1'''''''' "" the U<;\eI' IWl< .... Iheor ..,.,l""}' ""ndanz '"""'" I'o!.,..,., Ihc ua,.,. miD< • u--n )It the illlll.lnllOll one!"""" off th< pon:c:laI~ knob:! fto>m till< 12 o'clock J>DI'" ~ kft ... nglll LO 1oc:II • ......,OaI pDIIIIS .. b .>Jld ~ • . 1.1=-th< ~ ..... "" bct"'CCl! IM~" ot lenlllrW pomI1 A. '" B. B de C. we&:: A- Th= .. 110 bOCdLO WISOI<kr Iho:>c conntaJOftS W!1css a ~ ~Ri >ppI':oVL If \his CICC\In., unooIdor ond ..,.,fy u.. ......m", fadt. Th= >Indd be no ~ found bctWtttt my of !b<: tine ....... oaI p<)l"" >no! !be ..,.... shaftlcase ~ ~ ....... 1.1_1.2_

R~ rldd~iIodUo&<- Refer., Iht iltu.ntioo ~ ot .... <1CIIer 1'tIIOI'. n.. fidd wUldinz eonnecticns .... noocd .. Ih< ( . ) aM 1- ) tcN"",tioo" of Ih< m:1 &. "' ...... smped ,.;i:a,. Me>o>rt the ~ • ..toe willi your ohnrn<tor b<,,"CC1> Ihesc \WI> _bOD points. n.... ca~ .... Iioi .. """" ..,. be IltISCIdered lin .... a f .... lry rudiq 'fJPCOR. If !has occun .......... the cmnection and verify Iho <=$Ur"oI% tc.><IulJ.. Wilt! lhoso< <Om><CtJOn5 lifted. !hue should be 110 '(lnbIWl'Y

'" It.: ma shafi. This would ,ndIcaI< a ""'" 10 i""Und ,.,th ...... I\dc! ... 'IIIIII", ..

Dio4G. S .. diodes ~ moumed "" the ucilef ItICOr, Ib.y m::. gfy !he N:. >dIap: ~ by lilt 11>= """"" of ...... iliary .. -.ndiDp 10 DC voIuo~ and !Iq)pIy !Ius DC voIIage 10 !he _0, fItJd .. indinp.-

-.~ 11 OIIIIIS _ flI( 010.

-----.[~~~:;~'~'~ ... ~~----------~ IF ,_rn

51

1ht d>O<les.,., be ea><ly .:hecW ,n pb<. " '-Im !he ...... or ~ common """""""''''' 12· ... 1< h'rh be:Im bcdl,ghI ""Ib.. """" JIl"'P'" lads ond Ihe gcn.=lor', 12 ..... ,.,..."g baI!<ry

A shan or "" open In ~ di<d< ..... c".ly be found ',nth Iho ~ wl\boul ha,"", IQ ulISOIde: :ond ...,1>1< <Od> iII<l& II>

chcd " wllll an ohmmeIc,

IIIln: ",,,.,,..p''''! to cAe<* diDtir. '" p/D« • ...,It "" oNr.m<"" .. iU C ...... ~nDtI~"'" rmtU,,!' "" dot tIiodn dIU '0 1M /SlU,IIDlY .. UldVo,J- C<>nm!c1JO<I1.

v,1I<n ...... "'" aams !he diWe. as illum->ltd. ....,. paws 1IIn>uiI>!he di<>:k ~ !he he>dlizh: II> p ' ~p!y.

Rrvenc: !he leach aa= !he <bo<k. Thr; doo& .muld bi<>::~ >OItog. pa<<>ft, """"'" iL"",,!he ho:IdhKf!< s/'oJld "'" JIooo-. or " may ,,,,,,, fatDlly_

a. $IIauId.!he Ilulb _ pow ,,',III Ie>ds o:onnccl<d ", bOIl! dirocuon5.!he doode IS open ,lIIemally.

h. SbooJId!he Ilulb JIow Wlth leach CQr!DtCICd '" boIh d!rtcuoou. !he diadc IS ~ ,nIanaIly.

1ft boIh a ond b abo-"c. !he diodo ohould bo. .-.pIrc<1 a..ck Ihe rniSWlOl: val .... of tho !"OUIUbl iiold "" .. ,hop and tho lII!eJTIly of tho ...,...,... c<lllD<Cl<d beoo,.... !he field ... ,I>CtiDp.

RouuiI!, FWd ltindinrr 1.(J-8.(J oIvIt. (Readin! Llkcn bwoo .... D tho ,_lUI "- win", ",-,res conne<:ted to !he I" )~ (_) 1Cnni1l>:l. of Ihe u.ct'" rotor as .-.. 1ft !he ,llustr;>l><lll..1

hrj, .:i ..... (Inn", .. roadi" .. botwe= boIh yclJoo.- Io3Cb &Ii!:d from !he (. ) and (_) t<mlJrWs ... !he .xc,", lO'Ot.) A WIn«! posI-=ioIcr win dIostmy !he """"'''' field 2nd """'" tho !£ 0UIpu!. voila&" to drop '" =c.

7.6KW 8i GENERATOR SINGLE PHASE

MEASlIlJNG RESlSTAHCE

Main Stator Windings I. &-,11. Tho......wICC: ,'3IIIe IS ~ I!e,ween the

lilied Ieod ,.., Iivm "'" ,n<ulo<cd ",rmm;oI Ix:",," !he nn.fanner and Iea1 ~ [ilied from the 1£ = .... bIock.ln ordotlO paIIy ......... !he <WOf ,",,"dmrs of JfOUP _I. Iead.s sbauId Ix: [ilied from It.. Iaml .... block.

!. c;,.,., #2.. lb< ........ nce value is .... mnd bel ... =» th< hlied 1ad . 1 from...,.. ,n<uW£d!Crmll'Lll belaw Ihc InnS

fmntl and lead . llifled from "'" AI:: IUm>naI bIocl<. In ordot '" IOtaIly ....w. !he ....... ",'lD(\inp of"""" 'l . Ieod _2 sbauId bt lilted from !he o:mu .... block. __ ...... tt·n~

J,. M ..... SIDU>r AsuiJiIlI'} l+u.diJIp are me-=! between Iho double lads on "'" AC 1UmJ.w of die bndge ~fIct. ""flIuued from !he =tilicr :snd "'" <Iouble k:od UD_ nI pnIIII t;CIDI><CbOrI of the regulawr plu,. __ -...~ I.S.'''_ IIlTE; No ~ JiIo<JJ ~ found klWU1I ~idw, of thnr ~t ''''''1M IN to rJw ~1'(lI(>, =~

Compouad TtallSformer C""", I m<a<ur<d be"' ..... Lead . 10. "'" AC lel'Tllinal bIorl llld Lead ~ ....... J.DICtioD boo. Wi bodIleads aIona .. 1111 lead 109 aim. lenninal block. C""", l _ between Lead lIS aim. !£ ICmIinal

bled lAd Lead '"' .. "'" j<m«ioo:I block. Uli bodIlads ...... wiIb lead ~ • II-.: IemUI>aI bI<x:k-_.. _-"I.O,'·Utl_

52

... ~ <l(lnn<Ctu)n voI"'i<" COI'II'>eCtJOnlawn: the ..... ~ .,.. .... belwun thr _ I red

lead lifted from "'" l<:mUJ'I.>I ..... p :wi tho black :and ,,'III .. wtped lead "fled from the AC lerTn,nal block. __ -,..-... u· u _

VOlTAGE CONNECTION TERMow. "The .>ddioo.. of ihe !Ine ~()m><Cl>(In lerTnnw .. for !he '1IoCfea5C or <Iectuoe of fuU·1o.l vol!.>.., OUtpuL Should fuU· Io.l YOhaJe fall ""low 108 ~ts. scleclln: ~ tuih« number """" ..... .<tnp !..-;I 10 <:ODDOCI tho lead (red Of nod ODd ,.,;',le l " 'III suwly • luSher N:. >01\.11"' 10 tho ~x<J1<T """un dunnS full_1o.l ' , • .ti ... $ bnftP"ltho OUIJIIII voIlaJe of!he rcr.c· -". N ... 1o.l vo/tarc should be puperly adjusted by "''''nmlng tho c:om,>OWId \r.IIl$f(:l'fl>Cr. 121 - 124 vol ..... 61.5·62.0 henz. The....,.", should _ be used as • means of """"",ngun, for irIalrrectI)" adjllSlJncihe ......... Of·. no-load mI,'«

IIOTE: FtH tr<giM .pu~n:.i>djl<SUtfDl~ su E .... GINE It/J./USTMENl"S 1/1 rIus """"d

""'" on."", ... """""

7.6 KW BT SHORE POWER TRANSFER SWITCH CONNECTIONS If !be ,..uI1er COIIIICC1S shan: poo.'a" It> !hi: -=<er"s AC Cit· cun. Ill .. "..... be don< t.,. mean< of II>< SHORE POWER! OfF/SHIPS GEN. s...!h< tr>D>f.,. ... ',tch u-.. In lhedla-pm>o Ie> tho OFF po5IUOII. Ths ..... nd\ p<e'~ .. mullane-""" ClDMCCIJ<ift of ....... pow ... It> 1<'''"'''''' oucpuI.

A CAUTlOft ~ ,. 1M gt:MRW g~ r=J1t If .tiN" sbtn PfIJIfW IIItI ~III HIIM ~ffI CfltuJUtfti _ /be _ time. 1llis IJJII' M ~tl/t ~ is /MIt cntInIfI.'" U. .... ,M/i), It is fIw illsWlet's rapfItI

sibi/itrbJlUbs.m ~ At: ~_ ~

A CAUT10It Htnr IHtDr /eMJ t/MMJd be $hilt (Iff

lid .. witdlillg ~ pIIftr t. gea«2l111 ~ ., .;= IaN be- wbge ~ itJdKftI by -'feb;"g ri IIeny At ItwIs CHI In. -' kitIg gpen,.d -r_~t.u.udtfr..,~.

tile genent«.

Sbore Power ConnecliollS (60

IIITI: o;",rr>m ._. <D<lMctiDIu "" a /WD-",,~ 110 >'OIl $}',""'- Flu .. wu·,.i", ~'J""" ..... lM dimed Ju..,. "" IN ow, i00i1.,.

53

230 Vottl5O Hertz Two Wire CoIlfiguratilln r;",,,:< It!< trpO<",on,ns of "'" ""'~. p""'nd \tOO on "'" I<r_ ",mal b/o;:k 10 th< I"ncr.>\Of CHI:..

o 0 0

0=

u

!~~~

r-+~==='~'~' t:-11

• In • J •

SPECIFICATIONS· 7.6KW BTO GENERATOR

EIIGIIJE SPECtRCATIOUS

--C ,0.--,-_ .. C .. __ ... -_.Coo.o _ ,

-.... ~,-~ -

_1DrqtIt. aD 4>00< _ -----..., 111 ",. ,1111)_~ --t .... -.. 1. •• ZA_P'6 ' l'II~

5f.Dta« __ to 1\:""1

~-- ....... -'" ~l'II '_Ili'"_ -"-............. ~V.6_151U_

mlll tUUII;!.) UUS .. CZJliIrlill.hII_ ..... c-....w ~25"(Ia"_lO_)

lII_1J' I

TUfjE-UP SPfCIACATlONS , -.... ----'-$piT_is-:! ------~ -"" ---'--... -... -..----.."

_,",(2I~. ___

(l1.1 .... a.o .. _-.IT'ITDt _CbstsQ- .... ~0IIe0s S,'!IIIOC e.r....Q"a IT a1CC .r.1.5 _ w _w ' __ ID~

1~_501w« ___ UIO_M_l

1120 . 71 • 0 CIIi(l~. S -0 Io'<mlI --.---lJD5 . ms.rroc:

FUEl SYSTEM Or>--. ... ---. . .. _ 1lD.:_ ... ...-.... oIO!> .. ...-I

---~ r me (b DE r-)

ELECTRiCAl SYSTEM SDnn;a.., 1 !-_ H_~

a-,c..., <100 . W)CdI:",""",,_ (C(.Aj Dt~__ SI __ tIII_

sa.... I~ __ 'HW

SMooe..... Qo. ... _ ..... OC_c.- .r.. .. __ occao;oo;CIm<I no - JIXI_~caIa)

-~r. •• --... _-..._"'" .""----

CODUNG SYSTEM

II'G • 110" f (77-.. Cl C a f \lClO.. __ _ -- m _ _

LUBRICATION SYSTEM

""-- ...... _.,.....----at_ "" ..... ___ Ij';lt -.. _.., ~IM_ ~ · 55I11i I2-S ·lJ~ ,_ .. DI~ ""'"o:c. CI' .. a;...

5.Ii JII. 11_':. _

AI: GENERATOR ISI/lGil PHASE) _.S090_ ~. SiooI!_ l20lII,m.oo_-IlI""",

:co _ . 50 ""'"

..... .., ~"''''.''1ooC .UII""'" III .......... 1A KW -1I0 1Ior:r (ltiX1...-) 1:!(1_,M""'" 12M~_5U'11.6_

U 1lW· !OItIrD:C1S1I1 'IftI T.IO_~"'''''

GENERATOR COOUNG ....... lIXIdlI Cia;-.j (8I11et1:: _ lICO 'IftI ____ \$'I; lOr 50 """ __ lW1I;1OO

~CoaiOo'" ~'''fO.S5'.-j w_ {«I1ItfII 0 llXlfllllll

5.0KW Be GENERATOR SINGLE PHASE DESCRIPTION Thr Be JenrnIIOf IS a bru5hleu. ,,['-acned I"neratDf wtuch ~u, ... ""Iy tho a."ln! fom: of III< alIlnc to produce .. N:: outpuL Thr!OUlor '-' 'wo .... ol ",ndinp, tho ItWO _ " 'mdinp and !he .XCI ... Wlndinp. When Ihe gen<nWI"

IS wned, res.du.al """""",m ,n .... four ....... U"I poles II>dua:s .. <urIaII .. tho .......- .. hoc!I!ben !<nenteS an ",,,,n br:a """",D1 III "'" ... c;<u ";ndinp.. "This muwal build up of ~ i~ !he four rotaUtol "'*" and in ..... ClIO""" ..,MiD&, qurlly ~ me _ "",nc ollhc ~10'js) and a rqubwl mcrJY fdd IS ...... mamWftOd In tilt sutor. At the ...... 11ID<. lflIs rqui1I«Ificld pradu<es a .,03dy ¥OI1&f< ,0

the ....... , ... ndinp who.:h con ...... be <In"", off It.: ",,,",,,. ..... , N:; I<:rmIDaI<UI"f"'IU:ACcqwpmenL Tho: generaor IS I "",p.pItnc. ~ 120 _AC, ..... """, or 1:!Of.!;I() vcIIl£ Ihm: ... -=. .. 60 ho:nt: or I to -01. AC rwo"""' ... no YOII AC IWO-~. at SO henz. RtJa 10 !he SPEClFlCIJIONS SCCbOII of chis manual for ......... or l2i'

Jnt<. Thr tcr>="""' <bu. pWt ""'" "'" voltage. elZTenlw I'rajtxncy r2linl 0/ ..... ~_ All AC """"I decal IS affiocd 10 II>< ,....,., of the Iouv<=;l ~ at ..... ~ 0Ild. A d..agram 01 the ___ At:. ""'tate CCIf\fICCOoou is pro-.-.dod ",,!hi: d«;aLAJlintt:p ConIrolk:r (IC) IS ~ Insode !he ce"'<*Of and wppi;.s a ~ DC c"""r< 10 Ih< ~ ...... , baIIay ....... Ibe cencncor is fUll",,,,,,

Fa< ".,... ;"f~ sec II>< INTI'£iRAL CON'TROllH OC OiARGER SC<'tioI> III 1M rnmmL

-~SCIEIUTI: WIT1I DC UJlERT CII,I,M';- cacLIT

•

c_ EIt!IU .--' ... C»KfIDlll ii~

D_ DC urmrr tILUIIOIIIIi CIIICUIT WIllI _~""D .-rEGAAI. ~

55

Circuit Breaker

A """"n ~r '" ,n>Ulled on :all .... :1< p/u>< WESlERfIEKE C.r>ef3I .... n... ctmIl! br-uer ""II""..,. """",olly dJ<axmca grr><nlO< I"l""'" ID <:i« of :11\ clcctnc:aI """laid. Thr clmJiI brWer ..... be """,u:oIIy oIwI off .. -lII:n .......... 01 "'" S'<ncr.olDl' to CMUre !No 1>0 P""""' " <OnWIJ u .. o "'" boa<.

NllTE: This t;i"'JiJl b~aU' U ",WlDbh aI a \\ 'ES11:RB£KJ; odd_ tit"" tt:Jrlhr ",."ul ~"""". C<If<l<ICt \'DIU"

\\'ESlERBEKE <kale'.

60 H~ . 5.0 KW Ci~ BrtcU' p".,.. ... ~, ~l!38 50 H= - 4.0 1(\1" C,,..,,,, g .. akI, Pan N~' 4T04

,

,--------------- -, ' I I I I I I I I

i q:J ~f':J ' ________ _ __ _ __ __ J ---

5.0KW Be GENERATOR TROUBLESHOOTING Tho: following ~I chort is designed to I"'" ..... "" ,I'l10 p"oblc:1, .. " 'hlcb m3)' be 0ftC0UJIIeted wnll Ih< .. np, and dual <:>paCl"'"' Be ~ ~ Owlng II> tho ... mp/Jc>ty of !be ""IU'prnenI >neI COIIlrob.. IroUbkVoooun, ..... lauvely easy • ......, "'" "'~ be'''-ten tau .. >nd . If"",,,~ ~ III mind IhaI a ~I< fun1arncmal "-Ied,e of d • .,lrir;· II} .. ""JIII'UI for ..... ~I- >neI oI ..... y. remember !hal lethal ...... ~ "'" pn:scnl In !ho t1mIiQy; \hm;f"",. utn:mc cautKIII is ~ .. t>rn ucubIesbooun, a ,.,...~ ~.

Oo>Iy a f~ ba..o lOOk are ~ for dmglXllI< and n:patt. n.... are hand '00Is: .. amp pmI>c and a quality ""It -ohmmac< ~ of rudtnl leu ItwI """ ohm due 10 \hi: precI-. n:qwred ,n , .. d"" <""IjiDiLI<'" wlnchnl ~

56

lid"", >IWTIpC1DI "'Y "'paLn. ,.. a cia' :III .. pI>lUlJOn of Ill< fRI*m :as possible. prder>bly fmm :in ,nd"tdu2I ./11 •

...... ng Ih< prOOJocm. h:I ...... ases. a... m>}' bnng to liP. ~ problem ",Iud> IS ttl""" LO "'" lII<Ohod 01 ~..,., r:>lh<r ""'" "., .. pmenl faul •. S .... , booic rq>aIr mots ,,,III )I0Il OIl tho onl~ tnp '" tho problem oquJpn'I<!II. ...rn ... diodes :and bndge re<ufio:r. SO """ d "'" prcbIem should be (",,,dID on< of tbi= .-1)" ~ f>MIS. the problem can be mnedied <:>rIy and effiaerdy.

5.0KW Be GENERATOR SINGLE PHASE DUAl. EXCITER No-LOAD VOlTAGE ADJUSTMEHT TlIese ,. ........... h3vt d""t HeItZ and ..... Ioad ...r.a:. aliJUS'. ,n."" ~onn'"'t''''' .. CldI capac'''''. Thr= an: ~"" ~ "'">liable f".. =h <"1"'--""". T...., conne<.1OB :orr far Her .. .. 1e<:I>OIl. 60 Hertz or :'iO Hmz. ...... three C"""''''<n. OIl. It&. :uw:l1I9. _ for..,.100<1 ""Lace odJustmen~

""'bon nuk.nJ: Henz <ban,.. or _Ioad....ru.,.. adJUWntnu ~as ioll .... -s.: I. Shu! Iho ~or ~'n.

1. Scl= !he ~ Heru <:On1lCCtl0fl 10 plut "'''' each capK~O< -«I. 60 Hcru. 1800 RPl>1 or XI. ":'iOHcm.. 1500 RPM n.. ~ ot/"c """~ .. each ~"Of. " 1. ,.g, and "'J. ",11 ha ....... ~tf.a on the no-Io>d YOlIaI' prod<>C<d b~ the: genom .... One COIlnectar from czh pnup """ "" pI"ued lIIID each capac"'''' No.Ioad woItqc will I~ or da:rc:>s< ~ 4 _ 6 AC "<lIt< be,........., conno:cu:n -" in ""Y pair """,bimll<ll> 10 ach~ the pr=-ribecl no-load vol ... ,.. as ill...m<e<l bdc<>.

q ""'"" a",,~

.on: W/I"" d"'''t'''' Hm:. ~M by W ~"""'- "" all"'" spud adflHl'M"l IN dv ,iurxtu Q"" I<MD~ ..... M mmk. ThL AC D.",",' ~.,., 1M ruminal I>i«b ""'" b<t ,d.,;"d foT ,II< .otu>g~ rmd Hen::. "'.Iw ~~d, 1M H*n::. pI~1 ~c ...... "'1M r:<lpat;ilDT ""'" b<t dlQllxn ft>r j() Herr.. (' 5) IN 60 Hen::. (l'6k 1M ~ t"""'" ... ,,. _ n b<t """'fId .1Im ~""jrr)m 115 ""'n. 50 Hut;. ... 1.W "'DIb. SO Hm;.

A WARNING: ~otSlIHISt be tl/sdlM'gftllIet~ IIMJdIItJg as thq ston dtlcttir;itr lIIId cu ,uclt ~ ,vimtiMJr Jdl41 ~ ft'lll1I'IIrn Ifis&¥HlMdH IrtIIIl their

ptllllrf SMItT%.

57

flJTt: s.ntpI) CIfW lM"'f'oXdm J ", • ., tUmJ""!' ~TlII ... ""~/Q,,d (p/as"" /oQ,td1~J Mm>"''''''' 7hu .. ·il/ dJxIJa~ "'" uu., .l«Intl1)..

Shore Power Connections If !II< ,......tier """"""" Iborc P"""ef '" I~ ,,,_I", A.C at"

an<. Ihls musI be """" by _ or Ih< Shore Pnw<:r T~n S .. ....,h. Sa :hi: InIlsfcr ..... Idt ........... m !he dl.~rwnl '" 11>: OFF po$I""" "Jhu; . ... ,Id! ~, .. :'''. $tmI.Iitan<:OU> <'"'''"'''''''' of ""'"' ptM"'" '0 ,.,.....00" _PI"

A CAUTION: ~ til'" ~IH t:H rtSItlt it .tilffr slrllt8".,-iItItI~.,-. .n _t:trd ., tile _ ~_ rur '"'" .t gawnllH tIua~ is ".,

tl1"m"H """1Ioo! -, .. r" It is I1Je ~lIers ~ /IiIffr lit .. It SIft.n AC ~_ WIt c~"

120 Volt/6O Hertz Three Wire Configuration --

[12$' _ ..... ]

N~' (2tII ' _ ..... 1

MOT1: No N OV e'l"'pmmL

230 VottJ50 Hertz Two Wire Configuration

5.0KW Be GENERATOR SINGLE PHASE SINGlE EXCrTER NO-UlAD VOUAGE AILIJSTMEtfT I. ~!he""-=<I....w pi ... .. the bEk ollho ~or. <~ Ib: I4C ICnrIIMI COIIMCl>OIt< "'"' !he <apaC,u..{. ).

1. SwlIho: JmOQIIII and a11OOO' " 10 Nft for 1PIJI'ID"11IOldy ~..., ITUn~. 10 ....... ,,~ can wvm up. Male ..... "'" ,. ....... IS oponllnl ............. MY eqlllpIIXm ......... , AC <_ i'nIm Iho J<:ft£fO'Ct' (Illal If,. _ off all clcan<al .pp ....... ). Make SUO'< lilt ......... spted flienl ) I, ccattnAdJua!he fuel ~ ~-. r-.;Ied 10 obta:a !he tomd ell ..... IJI"<d bdCR ~ ...

1. RcfcmJl, 10 .... N: kIod _ diopmIlIeIo<o, chock !he gcn<nl<I' .. ..... Io.I "DIIafc by .......... ntlhe YOIup ..,..,.. III< newallead IOId tho hQo.lcod ... i\h • ooh melet Mab: ..... you record dvt~. The ccncr-liar', no.lo.ad .... ,. IS L IS • l2A >oils .. 60.5 _ 61$ Hcrq.. If Ill< .... cupa II hi .... or ............ $ptQI'Jod. ....,

• .,. 11

rrrn '> 1 ~ : ~ 11lV!50ll1

----'.

-~-~

.a. SbI #/f tho: ~. ),take """' Ihe c:oma Hero: lead (<<I Kttu; JI6. or 50 Hertz pj) 11 pIuuo:IlIIID .... ~Il. .

A WARNING: Ctp:lttKf ..rI .lisdaged .., .. biIdIHIg _,., sf .. II«b/dfr_1aII ~ /I ",~ IftIUI cUIJr: __ ... IIiSc-.

~n.tbftr~_.

IIJre Sut!pIy ...... '*" c~'J .... ~,."w, ""'" ... ms,JQ:ed (pk:s:>c IttwIUJ ... .......tnw. Tlw .,;g 4uc:IoarJt ~' aUS! .l«tnat'J'-

58

AwARNtNG: De.""""'''''~.'''' ,.,. Mjus! 11II1II. It. ~. i$ ~.

,., upuittllf un ""wu".fI&5DD nit cUrp!. rHdlJ", ." wiring CMI ptNiIu ,,~a.!ee6iQ1 dIIN:t. 1D IItIiIItIM, .n ; IiIg t."~I1"" ~*j' ,trmn.IfIIt"&!laf.iI~ r~ _ ,.. ArIfo!n II .. CMifIIIt • ,.. ,..ntlK"S ",1 ..

S. Then: ~ ....... pilip ~ for .... npc ...... or .... · ....... . J. If8.8DCI,g t(Iht~·._loodooollqc 1$ _ . ""'" ~ !he Iowa rwrnbered pIua _ ..... nee:. the pIu, WIlh Ihe IICJ.' "':her numbc:r. If Ill< rcnm· 1<11", _Load ><>I ... " hlJh,1hm disconnect tho ho,n.. fIIm'IIletu! plus and con...a !he p/u, w,,11 the ..... Ioooa .....-. N(U thallho. pi", pruelllly C<IrlfttClOd II> Ilus ImNIIa! "'"Y be MrJ 11M ollhr II\tU pIup ...,.,w.o. .

'" If doe F"tf .... " oo-IoId "'*""' canrG be IdjmIEd ~ Iho. ..uuac ......,. 10 be IDCtUKd ....:I .... hops! .....ta.d """Ii abady == ... , to doe nchl '""" ...... or doe .aIta:e ......to 10 be IowauI """ Ibo ~ ...... bm:d pius IS already COl H d IIIaI adJUil doe _bad spwI and cbccl: Iho eat*1IO< rIlInp..

A WARMING; 1IbIt.r:.ttMtlu.~ ~H/:IN!~"" .. "pUa" .. MIT .. c.txt .trt ad/.t1wr ., .. aIIDt:I

j

~ TI£" II'IRf /$ SHMIIm U 1W.IS ..

----~~ CQIII'kCJD<$ C4¥ --

$eo doe OKiIN£ AOJf.'STMENT ICCUOII In 1lII> ...-.J for ,wJumNG 11IE ENGINE SPUD

•

5.0KW Be GENERATOR SINGLE PHASE INTEGRAL cumu:uER {I.C.) Tho " .. "", ContoUu (I C.) IS ." ~""'P""'Med ~ ..... Ih>o aoppho:I.. IX dIIrJIn, -. ....... ,..,....., 1UIftIJI, baa<r) .. bile Ito< ~ IS open""

CloarpIc \~: ao· 14JI >'01 .. DC Ooarc ........ p ..... ,." 0 - III- '""'PO DC

A o.q>aIW JfOUP 01 wtor ""ndiJIs:! suppIles AC ""'~ \0. lind,.. ,..;nh:t ~ <OmUI$ Ihc AC ~..,..,.. to 5I.IIlS'Ir .... I.e UIlIl Tho I.e unll senses tho '-" 0( .... SlIrUnl to.l.<''and 1iUf!PI .... DC ~ v.toen """ .. -.ded If you "'IJ'I'C' INlIhe I.e. .lIn IS foully (1hA ~ if ..... ~·H~ IS low). chod; Iho ch3r,,,,, <-=I and ,.·s coo .. , ..... ""'" as deocnb<d III Iho (""",,,'II, SIepL Ooed .:n a>MeCtIOII:I r ... cleanbftQs IIId bpa.c.s IIICIudInr Ihc ~ bel..., oepIK. ,"' .. I.e. ...... ImTE: '4'1voo'" ~_ ujint!JJ:med. IM/.C _ .. "Ill (ItDIiw. ~ ItIw cIrdIt"'l "" ... r .... o.a.-,..., tel_ .. .u'IM <If dot ,.,._ .. .". ..... tI.

The "*p c-run.. II rncunIed .....x !he JCftCf1IOI' ...... .......... Il:((IPOOM'(M' Then: II. ~ OUIP" .:IJItSI. "'"'" 0II1ht COIIG'IIiloo' ltaI ,.,;.u an- I DC "'*'Ie oucpuI adJllRmelll 01 ~ 1 "III ...

IIOT£: h' ... ' /ow .. ..". ~TJ dutrmaI. llv boll.w ~u ..... C'lmul SIN. dot bG!Ian rui.to,'. ftmct_ .. _ ' /oolttdJu ""'1MlI). wr.. ........ r npt«"" "" Nrly JI)'k CDII,>OIkr ... 1m W _'f' }>Iu "',.. ...othL ,......... IN ba11tlJ, ........." tJItd III

"' ..

. -o

ImIIW. .... ,iiOUDI .'G .... II

ImTE: urlNr 80IkI Cl1ft/~~ '-! ... -lulv,,. ... /oJ "'t""wIuwN2d:,~c~""" "" w.~~.

Testing the Battery Charging Circuit 1. B~ ROCIifiott

Nama! At: .... ........., 10 Iht ttCllIi<. ,,,,t.1< !III: ... ". II ~. 1100 rpm) IS ~ O<Y<II'Ilk

two N:. ~ OIl clio: lind,. """fief f .... inu.nred).

AC >Obgo RIM"" 10 "'" bncI,., """fM:t 11pp'O""'-)' No-«-! 00' Ihr _.,.,.,.. 16.0 _(>IliAC FuJI~..,.tbtl<....-a ..... 17.5 ,<>!UAC

NmnaI OC ~ 1\ItIftI"I OUt of .... """r... 1m .ob DC,) IS ~ ...... """ ,_ DC COIItICaIC>II5 "' ..

bnd", """tier; !hailS ~ """ • DC ..,.....,. NfIIIllIl from tho bndrr ~fia ,-,

No«..d alr IIor .-...-- 11.0 _o/u OC F ......... oIf .. rr-n1Or IIU .... tsOC

.1.. AC"~ G.i" ohm

Ldltho '-'ON:: " .... leldsol(!he bndrr rulIher0B6 me-. .... , '>MI' bcIwten these ,_leads .,<11 .. <>Im-= " *"dd -.-.e 0.1 ' oM\. r-:o ..... _..,. IhcuId ..- botw<= 1hao< ,_ Iuds """ Ih< 1ft"""! CO'

!be mIiII N:: staIOr """';"Il-l. T"'1iD& Ibo Briotrr 11.".,..,.,... (meta ..srd • SimpSOll 260)

a. 5o')'<IUr ohrnmeIcr'l 1aI. on AX I (. DC) and ... tho _0= h. Co::wu>o>:Itho (. ) pOS,u .. 1ud from !be ohrnaoet<f II>

poim 11-4. TIIbao,tho otwnme<.'1 ......... H lead.. ~laOJdIpcmts . l, .2. .1,_fj The ......... ........ IbauId ~ DO ~ ' ot ""y eltho _ ........

Co ~ tho ~ (. ) Iud from """" " ...:I .........., Ih< oqar... (-) Iud, ~ oou:h pamts . 1, ~ __ . ) Thr o/ItnJnaa" ........ w..Id cIdIca ........ cKb ..- IS IOUeIIcd.

d- t-"" <toe ......... <>I.,.~ H Iud on ...... ~ ........ pouIll5 ""'" IIw ",,",U'" Iud. 1'00 ddIcaoooo ...., .......

I<.. PIa:c III< paul .. (. )Iead on poolll _I _1Iw n<p!m: H kid on pouIl , ) Thr ohtt'u'MIcr .n JIIoukl DOt

rquIU .., ddkcuon (DO deft""""" ,ndIcaocd ,niiBll< 1'tSISWIot~ Re........ Ihes< CotUICC"" ... a.nd Ih< Dhmme.., sbould.,am f't1lS'"f III> dell<ctJoft. If Ih< ~Iier fails arty el lh< prr.'>OUJ IO$U ( " ,E). n:pIa<. tho: =, Iic:r btauo< .... <1<1..", .. ,

lUTE: lJijfrRftl fJpU """"" h""w tI/ lUI _ ....... procb« ~ """ ... s..tu.

-~

5.0KW Be GENERATOR SINGLE PHASE Ballast Resistor 0.5 Ohm

E>rly controllen haVIDI <Ius """ ..... ill Iho DC ch>rzinl cir· CUI. If<: of IlIe 1Ivce lad type.. n.c", line \ead !)'peS conoi<! ol.,\ha line 'f'adc plugs In ~ or CQftiISl of "'"'" ""'" leads from It!< "",",oIler.

Iv> 1C ........ is induttd in !lae windiop by m. I'OIaIIIJ field. Ouki", Iho rESJduoI .m.,. cupa from 1bs "'~ ~ .x...m.n. Ihc un .... of d>o: ...,ndin& '""'"" ~ ""S!"" ~ 'o'IJUAGE: SiIIIO c.,.. _ I •. I . _ ~ _ . ... --. _~_ 14 - 111_11;_..:10 ..... ___ 1- ._11;_ .... ....... I\C 001 . .... I>< ...........t ........ !he capa<"U'-1$} .. ilik Iht ,.,........ iI oper3Iit1l. 1lu$ voIII£" m.oy be .. hi'" as 400 10 500 vollS IIC This .....ttas. buildup is ~ ....... =, .... windings ddrJ<: !he ap>CItor(s) and Iho ~I(lt(.) di«:barJt b.d: ;"10 !he cllCi .... wiDCliop. ThIs 1£ YOItage readiol .. un.. bet ....... !he 0060 Hem ~ _ tilt • COIIIIOClioII plul&"d imo Ihe apa<:KoI'\I) "","10 Iho ~ "oper1Iti,.. .. "" ~ Hmz (6l.5 - 62.0). This /Iowo, ...... ..... , AC '" tho e.circ ... -iftdiDp pmduces • phase-imbalonce rypc Q( Mid Ih>t dfecu II>< ..... ihory "'1ndinp: • bm<fiCl.al tes.uIIlhaI procJu<:n p>d __ ...,;"'~

utics for !Ius 'YP" cl ,...:nccr. To .... uun: !he resisuncc val"" 01 m.. e=1Cf ",ndiop. Ioca!o the <19 and Iho - SO Honz oapaci1cr """""""'.

IOTf; 110m IIIIlIIlHrrJ capaci __ C'OIIfttnUu aitr.- til. 18. <llldrJ: qnd "'" H",::. ~ lf5()aNf #60.

UopIu, ""'1 0Ih<r c"""""'''''''' ~ the ~,or('l I>QtJnl Ih<>r pooitiooI on II>< ~. Pbce On< lead ot!he ohmmeter OIl pluJ COIInccUOfl "'l .M the atMr lead on plU! """"",. IIOfI _30 Hettz. Mca=e IlIe ~t<WI« ...t... or !hi: CIlC".t w,<>dtng< OIc:k 10 make ..... <h<n:" ""CO<Il,n .. 'y to til< g:roundI~or casc from .,111<. or \Ix ''''' ' Iad5. Also check",", no <""""WI)' ex"'" bet"...," .,!h<r "'" ~ Hem pi .. , or !he !19 plu, :lJ>d "')1 of lhe!!PIn """" ",-mel,ngs Ic:>d. "" tho IIC """"~ block If conun"u)' " found here. 3 ,:.uk e.usu be,,,,=,, these two ...... Id'''1 goufl<.-

ftB.D-TESTING THE CAPACITOR WI'" • ~,nr meter. = "'" e>paCl1Of folk".,,", the ,1>mUCIiOnI mclud<d """" "'" me'er. md almp'lI" the rnulu wnlJlh!: ........ ~ on "'" c:ap11"l1Of. ""'hom a capac""" meIef is DOl a-o"';labIe. perform the [0I1owm, W9{II<: ~

L Mar1a", """"..,!hey may be: reaac:bed cor=:Il)".

unpI"I "'" conne<:llOnO from the capaalOf

l. WI"'. J'Il'I'PC'. ""'" KrtIOS the ''''' conn<:CIIOfl'I CAf'D'oO'I ,n "'" previous ~p_ 1hI1 ~nsures the capac""" IS du· c:harr;cd as II W<I<Ild be: .. shu/dc)wn.

1. Wllh ... ohmmeu:r ~ 011 "'" hi", R ..".. pb« '" pill> , +) lead COl 011< capac"Of """,...,..,"'" and !he nepU"" I· ) lead OfIW """'" capocilllf con...ru<llL A "'~ ohouId be: r1::1IpaOIOf. nus ,"""~s • pre""mably JOOdcapacMOI .

4. \ndieM ....... 01. d<f<CtM capoc;1Of:

a. Z<ro rosisunc< ar "" _ '" te1oSWIC< ,~"" (shortd

""""""

60

b. IMniI< ,...;.,''''''' (opal capac""'). c:. No COfIDNn'Y should be: {"",nd bc:tWCCD !be: capac,''''''

COfUIOCI>On!; and .... ~'Of·. caK .... ~_

S. DpKn .... Ralnp (C~,.,,,tor meier)

a. Sing\< CapaCTIOf Unll.: 23.0 !TIItfOf=ldo 1uF) S' b. Dual C3paciIOf Units; 3 LS ",.:mCands luF) 5'

IIOTE: Rmu!1I~ .. rr jc<uI4 on W CtJpDCiltx c ... ~ •

MOTE; 7Jv 11I.;k, .m, l. c..",xiJDr >NNk1s ... Oti " 1.1'.0 micm{i:uod c"PfX'k>' 1111 MJo' motk/ ""lit CQp«"D' !UUU ..... iIa. .. " JI.1 _t'Cf-..rad C<lp<>C1''''- \\'M~ rrp/«Jlli " capacila, '" <I1Acr"" t(Jrlv """'~ 0'" 1a1~1 modd. ml~'" rhm IN CO<7rCt ""Oti N1pOC<lC' <J

uurallod. TN. c..",x1JOr "'''~I IS martLd on ,;,~ /to ... ""

"'IN <t>pI1C1llJ" 210 Miorlfamd cllp<lri1o, PN OJJ9B5 JI.l Mi£:rufi=d a:p<IC1JOr PN 03597&

5.0KW Be GENERATOR SINGLE PHASE &. r! ""', IX." ~""UbQOo (low Of "",At:. Qu<pUI ""'~) 110:

tcD<nll)< ""'Y be uc><td .... ng 12""'" DC w..cn from It.. "",~'. >:.v IIRI b.,,01)' TIn. -olLar< "~Iocd ~ "'" wSO >nd ~ Ie3ds of Ibc C>.Oltr am." ... ud"'P .. .,do :any ocher numb:rt:d i<.aoh unpIuuc<l from "'" apacn<n('}. Tho: ~'.1'f%tJ(IOI ng l'Wtw., .. ,II hell' <ktrnruD< II;> foul!.

11 " "

61

7. DwtftI12 ,"OIl <.cot>!"",. ""'''''' ""~. ""'~ :J« "" ........

... to. w&hl n", "' .... 0UIpuI voi .. !" WIth <he Io.idiDJ 01

Ib: en""".....,"'. r"""h"r_ from !he eo""""Qf oDd WlU ondi<:>l<. f;wl, In Ih: INIn .... or WI"""'''

to. No rue '" very ,lip.. nsc: In !be 0UlpUI volta!" will mdicw: • (>Ill, In till< ace,"'r "'''';'''10.

Co Normal 0UlpU' voItage:os ",",,'hod:II><M:. chock =, ........ am apoc",,,«).

5.0KW Be GENERATOR SINGLE PHASE Testing Component Resistance Values

Rotating Field/Auxiliary Windings and Diodes T_ ..... 0( ..... ..:IiD" "'" found In "'" moor ... mbly. All AC >dta", IS ~ In tv..) poup5 of "lJId.~p .. 1IIo: rotOt

IJ,nIS '" .. d rpn. The AC ..... ,. puocs """"Ib ea<h 01 !he two dtodel mawII...s "",\he osobicd fiollln: JU<I. ber"", Ihe ""'" cm<t ~,. The A.C ."., """" .. <hm~ 1(1 1 OC :md "'" DC ~ .. ~ 1Iwoup. Iho: """ JI"OUP5 of rowm, field wuw!inp ,...,.tuc'''1 • DC field iIIIIlII!d these <o.UldlllP. nu. field affeas "'" AC WIndt", of II>< ,_ nwn <UIQr poup< mducJng an AC W>ItIgc ID !hc<c ,nDdinp thai .. ... -all>blc alW AC t.nn,na1 bIo<;k connectIOIll.

I. RotatitII FocldlAllxlliary Wi""i",. 5.0KWBCG 3.8Ohm

To<hec:Jr. Iht ~ v:alur$. rotal< Iho: ..,~'.<nnk. WJ1w pooIOOII !he diode(o) OIl the I"nena', shaft .. 12 o·cIocI<. To malo:<: • """,k died: of ""'"" """";np. ~ !be <Iiodo IS O K and ~ Qa< of "'" ~ \er'. leads "" the <OIU><CtIOboo,e. If. dislUlCl dlf_ r""""" IS MOOd "' !be ohm v:aI .... catt:falIy 1ID$OIdor !be lead OIl "'" lOp 0( Ihe diode ond ..",....... "'" diode ""'" ill isoIIIcd "'* sink "';Bllwn .. -al1cd. deep ,,'ell 1116 III (II mm) soc:lo:t.

IIJTE: TN ~ /W'" sW: rlIot 1M IiioIk Ilonads JIll"

.,.,. "" beN autfiJ1y ooubotud 10 -u uuitlr G<uu '" ~ .... W,th tho: diode removed, bach lead!! r ... Ihe lint I""'P of IIIWInl flcldfauxilia'y .......w.p WIll bc iooIated ""'" 110 1DI£I'f<=ICC: {10m • p<:><:<ibly r ... fIy di<x:\I:.

Cl...:k "'" ~ """'" of tho """"01 ..indin" by pboml !Ix """"""\er', IeadI; ><:rOo> "'" ..... upos«!

'"" Also. "";fy IN! no COIIII""''Y aim ~ Ihes<: .......d. "'I' and the moor >IIafi by lea,,,,.,,,,,,, o/IInrncI<:t lead ....,hod 10 "'" Wlnd;"1 Ie.>d ~ Ib: othef ohmmcler lead lOUclunl "'" ohaft: 110 CCIftllow'Y dx>ulcI ........ If conlDl,,· dY IS fOlllld • • sIIan. t1JStt_ Rq>caIIIu< ...... obod on Ih< secone! &m'P of ...uunp. Rou<e II>< ""pnI<.' <nnk>hatllSO" '0 pDOlllOllW second diode .vMI connectlCfl5 .. 12 o·clocl.. No continuIIY obouId be found beI...:en Ih«e No.''''''''' . """I ' ~60 S,mP>"" "BOloi Mru:r To check !he diode. unsolder !he <:OIItICCbM from ,be "'" o f!he diode Place one oIwrune,.,. Ie:.:! on ..... corme<''''' '"" ..... "'" of ..... dJOdc and ..... <)(her ohm .... "" Ie:.:! '0 II", diw.·, b:IK. Then '""""'" !he pooIuotI 0( III< otonmnc, ....

H

A 100.-~ <hould be {"""" wnll !he IeacI:i '" ".,. dirttUOll. ord 'nfinite '""OW\Ce (bIocklniJ III "'" 0lI"C di=uan. Ooff=n, """en ,'"U re:Id "'!f«nll rnn<anc< values Ikou~ Ih< <bode.

IIOTE; DiJ/~nf01 "",U', motk/s may .no.. ,fjJf~"'" """" wJwJ. boa J.hixJd nad W J""'" fo' /JodI d.ot!IJ.

o.:deRauol'l600&mp< 26Arnp< The <tiodo., ralInJ .. r.,. in eun. of me c,,",m·, rect""' · _ M .... ijkely a diode r ... lure will .....,1, from Oft

o..,spc:<:d ... load surge.

Main Stator Windings SIIIII< Dual

c.pac..... Cop.ao::IIQr

0.6 Otuno O.-l Ohms. '" ."'" O.3Ohns

RaiduaI "lI.laJC meaoured be,ween ,,1 __ 3 and ~ wIll be 2-3 vol .. A.C btrwa:o each paiJ of Iead< .. "'" 1rmII".J bioclc nu. ....... 1d be an iodK:ahon!hallh< _OJ" ""O><Iin" :on. oby. OIo<:k excilCf Wlncb,,&, and :auficw!y ..... .., .. Ih<

""'""' [-b···········;·, , , · ,

'b " • • • • • • • • • •• : I ' _______ • ____ __ ...1

UmJiNJI /Hod:. ant! flO' Ur. ""Y """",,*<>1 onU,. ~ GTf

'''-'n k_,,.,.;:.,,~;-., r I • 3

o 0 0

~ l ~

Gn>.Ip _ I - Meawre resauance .. -at ... be, ........ <enrulllli .... ,Ih lead _ I 0fId l£mUtIal WlIh 10:.:1 - 3. (a..:d thai """" IS "" con""""y of Group .l Wlndlll" 'OJ Iho ~ """nd.1 Group #2 - Meawn: teSl>unce n1 ... be~'Cen ICmImaI ""'" lead ~ _ ItnII.IOJJ WlIh Iad.o. (OIo<:k """ """" .. .,., O(Jnb"u"Y of Grwp ~ windiop I<> Iho case """nd.)

O!eck fOJ" a posUblc ....., beI","'Cen me ""'0 pCiUp< of ""'OJ" ","'UMbnp by plKlIIg """ lead of!he Dl"lmm<l<' on ..... ICrmJ· .w .. ltb!he -.>r lead _3 and Ihe Olhor OJhmmcoa Ie:>d "" "'" rarrnnal wuh ~ Ic.od 006. ~.mould be /IOconllm;lOY bel......,n Ih< """',....,ps of " ,""" ... ,ndlnp .

SPECIFICATIONS· 5.0KW BCD GENERATOR

ENGINE SPECIFICATIONS

----m._ .,,.~

~

..... D<Jo<a'Ci4 ~.~ ~ ... -_.-~ ... (111100 """J ttm... ~ -

2-515 ·2..16-.165 .10 .... ) t]'ti, Vti-. [111 . 10 ..... '

~<mC m... (IIIo9&-"l oIUl aoc """'" (0.l0I ..... ) 1 - 3 - ~

~--- ... ~ ... V .. (l'Iq<a)

"' ~ til """" (f;Ilt mml .,,-_ lU ..... (*l5..o_) UIOgII:<lU_~'_1

""II!o {'_1IIIl m"'I1ZUIil;i5l

1l1 _ (11i5 11«). lDlIl"" UJ_ {U~.\IIIXI .....

TUNE-UP SPECIRCATIorJS

-~---

391 ""' (21 ~ .. 2!Il rom _

{.1..! .... GO~ _~1,.1ITDC _ Closes ~l·.ol!IlC ....... O""~l·!IiIIX <"-CII:ocs ,,. ATDC

-" _ •. 'ItO_50 I1e<'::: 1500 _ ~ '""" _ ............ O • ..,...(O.l5 .... ,

19111 . .. 2 .... (1«1 . 10 II;IC:I\ZI

At GEfJERATOR (SlllGLE PHASE) _.SftgII-waoo· SOoo:I/I! """"" ------'"

,21)....,.,·60_ m_-5011n' .5'10 '" _ .. Id_

101IInI 1~ ... 1OIa1l ... .... iiO filii: (11110 'II'Dll~ _'Ui Arnrs 12D'700"",,"6t2OJ_ 50 itorI: (15Cl1 'll"'l ZlO _ " MIc>o -- .... _ .......... .-_o ... ...: ____ a: (~EurtaI __

63

ElECTRiCAl SYSTEM

-~-

11-_ t-J __

JCI) -!D)~~ Jqo (tt.q

U-Vol.~

-~-<Il_j .. ,uJ. 'U_ 115 . 1(0 ..... 1_ tdi:l1 10~1t 13"'_OCf"!;ontrDJ

fUEl S¥STIM ,-_ ... -..-... -1io.1_ ... _ <lin; " <5 ... "9>«1

-~-Iypt " . SO mx: (s.!"", r""o.." (:<rMr)

(!IClI' IICl)I.j 19 . S· IITDC (llelut fOCI Oeid c.., (ICD8)

-~ ~ (!CO' I!CIIAI Sp&oo!alt. lot ..... 11IClIII) -... -.-2'.& "'" {O.!Iil gm,KlIXI' ~ Jl1 "'" (U57I7 __ HBC1lI)

COOLING SYSTEM ffI$II_ ....... -. ... I.,. aJNrolocl _ .. """""'Ott

~ la_ .... , 11\1· 110" F {71 . !Ia" Cl frosIo_"""'* ~wo. __ "'_ -------

6.5 - UUS_(2'U-53""'l~ _eo ;o"" ...,_~

• =1lJI_l

LUBRICATION SYSTEM -.-.... -... _ ..., _.,-"' .-......... l1li_"'--fUI ..... ___ .,.,.

U u.s. ... flJX\-..1

3!i - ~";IU-U~

AA.., I • • OorClr<l. SO< la, l trw-lIl. ,_

GErJERATOR COOUNG -M"'Qt _ 17S - ZOO" t .. 95 - 5.!;/;"",,) (III Hoot>: It lK1l '1"1) lOre __ ""'" 15,; 1tJ150*t' __ • 1S!a7 __

,,-eor- lUm~"""'1 _h ...... \MNtlrO ' KIl ... )

SPECIAL TOOLS - GENERATOR FIELD FABRJCATED TOOLS n..,.. dn-a:o ~ ~ _ by wbdo....pe Icoh <:all be mIde 10 aunt '" Ihr mn<»'aI of Iho smmoor end from Ibo ........ 311d ...... ~ of ........ '"'_ cndDII ""'...,. ... A Ioc:II machmc """ <hauId bo >bIo 10 r....".., ~ ""'" • ~ modeso p""e. !lui lint d>«k ,..,11'1 )'OUJ IoQI WESlUlBEKf. de ... 10"" ,f ~ tooI~ .... 001 ttand for lou\.

MoIIsing Puller Tool n. ...... a1 ........ !Ix be>na& In !be .......... hoo.&ft, '" be a-Ir pushed «r2IP< off dot ~ "-""J"--' If .... 01Il10 _ ~ a.otlla< ~ bolo .. "'" polot ............ II> be _Idcd DOl !lie cnd d Iho eye boll. Ibas ..... ......, be able II) pod1 Ibt bun ... bKk ..... place _ Mly ....... a'. PIeHO ref ... IQ d'OO dra .. ,,,,, befon: Iho ~ 101 end IS ~veo1

-~IfB.II FUItIC.mII

_Colli' _

64

Uftillg Eye Tool ThIs ltd :aIkrwJ ~ ~~ 10 "'II'd) =no'>" .... ~ cnd ""'" the e.o" ... ~' ow..-tm>, Ihti ~ EIId LIn,,,, E,.. "' .... four ..,"',.. _. Io.:acd ut><lef Ihc: c"""",, ~ Tu IOIC din LafUDI Eye. ~>'e .... ~or·. C<lDtmI p;ancl:and Io('rtwlh< LIt"'1I E}< 10 ,"" It""""'" end

Disk Alignmetrt Tool

c:-..,.,. • ........ ---.. Thr.f, 0001 ~ a rncdIoaoc: \0 w.", mIIO'o" and ""all !he ,., ....... ~"" dISks by ... ""., .... <!db Wo'JIIIIh< On.., !'boo CiuocIo I'vL Tho: Pm f<:ftWS IfIIO III< t'lY"'httl ..., ...... ~ ,....... Abo Ihe poD hdps 10 support """'" of !be /UODf and Iho ............. v.cop wt.k ".-..0, Of repIK1n. ~ ......

MaenaI: en. M8 bait .... "t. .... lin _ madlonod off and 3 """' ... -.In .... , ~ ..... , ". !he INIChinod end

Pilot Tool .... -,

_."

SERVICE DATA I STANDARDS AND LIMITS· 7.6KW/5.D KW GENERATORS -- Spoc;Iied ~_ / 5tanIIari _-I COMPRESSIOH I lIMING

~~ ___ '6llO'"m,... - ,,-~----,~"~ ~ ("'""I a..5_""" Ftod i'IooCa> Oroo> 1 - 3 - I

q,<:m r~" sm; .--.---"""~ WTmng io=<j _____ ,9!;JQ"". 1.&00

! ''''IO.(I~

"'"""'" ...,

Repair UIniI iIodaa(lIl1l

J<H ... \zs~

____ _ II.OO!~)' _ _ ~.OOI. '" _~UI_=-___ 'O.29) (U ) t_'"---_._---"" (-,~

___ __ 0.05\ - tOll (tl ' U ) --4G)ol (~ 11

(-,~

-~ _.-VAlVES

__ o.-~_t~lm.1\

______ ~HI!I !9')

SlnnO-O. OMIU j _ .. Gullo CIR'>o<t~)

SInn Ie Guo! CIanra [lonMIJ

_c-W«> _f.-WVO

, l OS' (25.1l

"'11'1 110.71

U - u

_lUI i'IIIlov!Ss, ___ '01m (1.1j ____ 'OO1jlO.5) Mqn_l

__ 9"" __

1l0ll3 . UX.5jt01 ·o."J_U ' 2I(I.l)

...-Gar bIq.CIea:an<t _ ~..a_ tOOl ' O,01Cl.Om . 0(17) --O.Wo1(O.ZI

CoaIpoo .... Spec&<! V_ I ~ _-I """"" "'" ---""""" ... -~ '-== ,~

00<7('21

__ ._ -----'I·OWl I'HUI3l

----""'"

...... O,lOO< (tOll _ 0.«120 to,lIS)

:~-::=====;;:-:'~ ~. :: .... .uo,o QIIoGI tlioInNr-Sb':&o1 SS ... ,.,., "1'1

'-====== ,-

R .... 1JIIIit iIocIIes( nun)

0,00010.1)

ClaQra"~ Oro2l-0lA)19I;O,0l1'OOil<I--D1lOI (0.3) _ _____ ~OO1. o.az 003

fila. 050. 0 1!)

"""' .... _.-

65

--flO. ' CIIroIN_ .... .. ,Sb .. f\'PO ~, -Olll) CIwomo __ Cof _

,---------~." to... 0" No. 1 ~ -OJXII 1IlC15 -d!li) 001 . --'1.001 . c.oo! 1000 ' 0.01)

.0')6 - {lOll (Il15 -0.00) --"(15)

SERVICE DATA I STANDARDS AND LIMITS - 7.6KW/5.0 KW GENERATORS , • sto <iII __ /~ -"'" -.c_) --, a.tt1IIIG IIOIIIORIIIG

,~ ...... "" -IIftIW T _ _

'" -.... -" ~" _.-

.. . -----_.-.... ----.. .-.-.. c.. -""-.-

"'--"_ ... -IlCICXIII ·o~-a~ _ .G.IIOIi 10 IS!

--_ D.1m (O.D5)

~Cooo"""'_ _O.II:n !G-lQl

J ill! ·1U1IJ1 fl!ti -Un)

~'''' "DD6 ~-ol 51

"" ... '-1<0.151

f'1W-~

------u_

o1lOll (t 151

I 07t 127.l7) G.CIJIt 11.0)

1.07I IV.l1) _ o.OlJ(.l.o)

.GD06(G.ISl

, S~·$ __ /s-. ReNrUooil , . I-I _ooJ IN.ECt1ON lUll" CUUIWT -- --... - w ...... [1.- ' IIotr1 -- I UISIIi "".,

-- D l5 (It)

- _ IlDl l' fllI

o.c- .. _ ' ........ O_01t~ __ -'DO> 14191 ....... ~"' ".~ .... - U !JJM fl 0:0"""1 ,

" UD(lIII I'I .. 11lt(·1 0)

"-ShIll .... "'"' 401< 10' 1

66

TORQUE SPECIFICATIONS· 7.6KW AND 5.0KW GENERATORS

-... "'" fHJI1HG1

27 - 38 (l.a . 5.3)

2~·35 (3.3. U )

COIii .. :llit,j fItxI c.. M8 (' '1 ~. 28.2 (32· 3.5)

CooIaIt ~ 12·17 (1.6· 2.~)

CoolIn! ~ PI*y 12· 17 (U • 2.~1 CaoIn Te!npemn Serder __ 9· 13 (1.2.1.8)

CoobnIlempel3!ln S\lllllth_ 9· 13 (1.2 . 1.8)

Crari<sNII PIAey Nul. 1.116 (24) .n· 86 (IO • 12)

"CVIindtf tUlSOIIs (MIl MIl (12) 60Its I. 2. J \4 ·21 (2.0·3.0) Ml01'''j 8ab 4 -11 S4 -61(7.8-1.5)

C')iIiMef HW c- 2 . 3 (0.3 • IU5)

~ MoI.rI$ 2:l • J.I (32 . H )

....... _' ___ -'20.24 (2.1.3.3)

""'''''''''' ..... M30 ""-;;;;;;;:==".";'9 . J6.2 (4.0 . 5.0) ~boIIM10 (17) 61·63(8.5·9.5)

Glow PUg, 1.110 (121. 11 • ' 4.5(1.5 • to! Glow PUg Lad 'Mre FiImg NoA.

Mol (1) 0)-1.0(0.\·0.15)

....... -ReIieI PUIQer As5ell'tltf 28 9 • 36.2 (4.0 • 5.1)) • PUg 11 ·23 (1.5·2..2)

Idler Gear lIIru$t ~ -==::;:'5.23 (2.2 • 3.2) ~ Nozzle 10 E\oItJ _ 25.3·36.2 (3.5·4,0)

Ir'fICIIOII ~ AIr! Nut 18 - 22 (2.5 - 3.0)

~!'tIe NoA. M12 (17) _ 18· ZS{Z.5 -l.5)

~ I'wrcI D!Mfy V3IIIe HDtIer 10116 (11) 25 3 -28.2(3..5-3.1)

~ P!,mp 0rM Gear Lodo:NlII -29-51(4.0-1.0)

NOTE: H~ /isJLJ .. .....:ric. ""'" ...t..t.,..,." 4JjQIJqt>r. ".heeI 80l 1.11 0 (17) Ml0rNlialwMw..:. IOmm~~r. (17) .. 6c_' l7"""txlOSJ rIw/l= f1{dI~ IIohItud

' f'lll!l) iNIiauu ...... botb (if ~I_ It> ........ dw!

lIfl """ wtpd "" dwm "4- IM, .... ..-qwd. If Iht """' /law _1H6t -m DNl ~ tWt It> lot ~ lion; ... ., u twtd<J,.

Irt!a>on ~ Hobr San Ul0 (14) _____ 12 -10.1(1.0 -15)

~ 16·38 (5.0-60)

InQIIz ~ 12·17 (1 6· H I

M.w1BwrqCip )6. 38 (S.0-5.5)

NonIe ~ (lilIn;J I) envnl. M2Il(21 ) ..361-43 ,3 (S.0- 6.0)

""'" ........ "" 10'116 (21 ) __ 25.3 - 28.9t3.5 - 4 0)

Nal:l2 Urian eoa ~ Nul. 1.112 (ll} la.O - 21.6 (2.5 -3.0)

Oi 0.- IiDse PUg MIa (Ii) -36.1 - 4.S.3 (S.D - 6.0)

"'-M2Il(I7) 7.9-9.~ {'1-1.3)

Oil p., 1!0115 12 -11 (1.6 - 2.3)

OiPn:ssln~ 9-13 {1.2-U)

OiPnsscnSWll:tl 9-13 (1.2-\.8)

"''''''''''' _ ___ -"289-36.1 (' .0-5.0) Rear Oil Seal CiII ____ l1 • \. (1-5 • 2.0)

RacIII:r Arm AssembIt 11 - IS (1.5 - 2.2)

~ Ann Cow 1.8 - 2.9 (025 - DAD)

IItIdizI' Ccwer Nul. M6 (10) --3.6 - 5.0 (0.5 - 0.7)

IItIdizI' Shalt Itc*I-cbon Boa, 1.18(12) 10.' -15.9(1.5-22)

llII!rmosCIIlfausn;I & • 8 (0.1 • 1 1)

TIIDI'lQ Ge¥c. 12·11 (1.6 - 2A)

TOIQ.Ie Silmg SellOCIo'd-6- 9 (0.1- 1.2)

Waf Tenljllliillln Gu;Je.kln U16 (17) 1'.4 - 21 .6 (~.D· 5.0)

STANDARD HARDWARE TORQUES HOlE. lIttku s=td ...... _ for oS ~ ...... ...wy. ItH dw joIJaM"'I IiH'fW ,~ ~ .... 'Wut""'f stcNi.vrI ,..,""' ...... _. - H ... _n,n ...... - H ... _ ... _ .... , ~, 0'''1 --- • ~" 0.'2 --- ,. 1.1-115 1.U --- ,. '-.!>·111 2-11-10 ,-_ ..... - ,~ >3 1·:2.' ~" --- ,.

~ .. .. U 1_ ... __ " 110-11) ~ --- " <'f;UI'-1i tH-l

, ......... - """'" 2U1U ~ 1%D1! .... _

,~"'" ~., 15-10S

, .... - " ~ .. ~u ,2lIn*....:>our " 5(1_.' 11».0 ;_1I00I_ '" 111·JU lHO '_Il0l-'' ,. -a'-6l.S .~, ,---- " ltHO,1 ~ .. ,_ .. """'"'"' " "~ 10-120 ,--- " '''''' .... ,--- " ~,., IllHSO 1 _ _ _ , ~ ' J.1J ,_ ... - , M}·II"-l 130-"0 ,--- " ~ .. '~lU --- " 1~*' 1st-n o ,_ ... - , ~l_HU ,,~

,_II1II __ , UIl.HS4I1 u.o.:u -- _se.._ --- , "" - m"" '" lN~ --- ,~ ,"",51 O>U , ... \1-13 I.$-U ,_ ... -

'" 71 ,.12.5 ~ ~' '''' ... »" ,_ ... - " ,IWIU U~ ~- n-n ,.u ,_ ... - ,~ ... """ .... """ ~" H '" ,_ ... -" ~. ~" " .. ». ,,~ ,_ ... -'" JoIHIJ ~. 'M"" .~ .. ~

'M" - iJ-II

'" "" .n ''''0. 1 "' .. ~ 10Hl1

1OI.11:IU [01

~~ !. ~ j!: ~~

68

METRIC CONVERSIONS

, ~.~ ~ ~.OO , 0 _0187 ~ 0.7814 , 76.20 ~ 635.00 , 0.1181 ~ ,~,

• 101.60 ~ 762.1)0 • O.151li ~ 1.11111 , 0.1969 ~ 1.3180

10 MlWM£TERS., CEImMETER. lDOCDmMfillIS . \ MfTEfI . 39.37I11CHES 13.3 FEfTl

, , • ,

, •

, • ,

, ,

, , • , ,. I

,

0.05(18 C.0762 0.1016 0.1270

,~,

1.114 ~

,~

1.'2 .. E U,

" .. I I

, "

• , " "

• , "

, • , " .. I I

" " I I

"

.~

1..31520 ..",.,

.~,

.~

" , ,."

7S I I

"

" I

,.

69

, •

, ,

" I

"

w . ~ •. ~ 10.$1

'" , .. I I , I

" ..

• ,

~ ,~

,~

, • , " '" I

I .. '" I

'00

7.65529

19.au

n .n 31.32 39.62

14 .19 16.91 '9.02 21 .13

0'

' 0

INDEX AC Volu~~ Conncctl()lll; _ .••• _._ ..• __ S7. 58

Alternato. InspecctlOfl ............. __ ....... __ ......... _._40

Alternator Teu,ni .........••. .. _ .. ___ ...•......•.•••.••. .. __ 39 Block · C ylinde. ........ _____ .. _, . __ .... ___ 19 Bn.d, c R« lIfie._ ...•.. __ . ___ _ .... ___ . .50 C1m.sh~. ___ .. _.. _ ...... _._... . .. ___ .. _1 4

Cm:",n B~akc:r · G¢nentor __ ._ _ _ ._.-46. 55

Con neclll'lJl: Rod ........ ......... • .. _ .............. 15 ComP=SIOfl·EnIl IllIi ..• _ ..•• _._....... .. _ ............ .38 Coolanl Corculal,na pump ...... ........ _ ............... ......... JO

C~" ....... ..._ ... _........ .... ._17 CyhndcrBlock _.. _ 19 C) hndcr Had. imprcu on ._ ... ________ •••• _ _ ... 10 C) hndcr Had.1nstall _ ... __ ... _ ... _._ ....... _ ... 10 Cyhndcr Head. Rcmo~ •• _ ....... _._ ................. ... 9 C) hndcr Block Irupecuon .................. _ ................... .19

Cyhnck. Head Bolt PJ,uem •... _ ... _ .................... _.9. 12 Elecmc- Moton · Chm ...... ......... _ ... _ ........... _ 45 EII,i"" Adjultmel'llS ....... ___ .. ____ • __ •.... ........37 EnJ;,nc: A55embly .................. _ .. _ ... ___ ............. _ .. 22 Ea,i"" ComprniIOfl •. _ •• _ .... _ . __ ...•• _ ••••.••........ _ . .38 Eri,ine DIsassembly . ....... __ ....... _ ..... .................. _ .

Eall''''' Speci lintions ............... __ .................. .. . >1. 63 ElhlU$l Mamfold ............ _ ..... _._ .......... _ ... ----24 Frequency _ AdJ"5tmenl . _____ . . ...... 37. 4S Fron, Oil Se3J ___ ~.. • •• ______ ••• .. ... _ 13

FuellnjeCtlOfl Pump ............... ___ .... _._ ......... .25 FucllnFdon __ •• _ .••....•...• _._._ ......... _ .......... .... _ ... 2 7

Fllell.," Pump ..................... __ .... ..••••....... . _ .... _.28 Fuel Run SOleJ101d ........... , .... ....... _ ........ _ .. _ .•••••. 21. 27 Ge3rs: •••• _ •••• _._ ••...•.••.••••••• _. ___ •••• _. __ . I~. I j Generawi' Disassembly __ ~ .. __ .• _ .. _ .••• H._. __ 8

Gmn:uor .... 'innl [),1Jf"m . ___ ._ ........... 46. ~9 Genentor Ma!n.enance ._ ....... .................... ___ •. 45 Gepemor Spccificallons ..... _ ....... _ .... _ .......... .54. 63 Genenlor InfOl'Tllauon ... ......... __ ..... _ .. ... ............. .... _ .. -15 Genemor Wirinl Schenwic _ ..... _ ............. _ .. .-12 44 Glow Plugs __ . __ .......... _ ..... _ ... _.__ :!II Governor ._ ................ __ . __ .. __ •• . ........ __ .20 Governor SIWi. __ .. _._ .. _ ... _ ..•.• J3

Heal Exclwlle • .. _ ...••••••• _ ........... .... ..................... .24 IdIerGear ._ ....................... .. ...... . _ ....................... 14. 15 In)eClion Pump. __ .......... _ .. _ ....... ................... _ .. _-. . .25 II'IJeCUOfI Pump Camshaft RemD' .. L._ ............. __ .14 !nj«IIOf1 linunJ _ •••• _. _ _____ ._ •••....•.... __ 26

lnJCClOf' - F""I ..... _ MlIn",n3f11;e . G¢ne-r.otor

Meme Con"cn,on Clwt ..•...•... . _ .. _ .. _ ..... .. 011 Pn-SSUK _.... _ 0.1 PRsw~ Sender ••. 011 PInsu~ S",',u:h 0 ,1 5eJJ • Fronl .. _._

Ol! Seoll - R.t.3r ... _ P~s Ofdenng _ ... ___ ._ ............ ......... ..

P1\.1on :uxl Piston R,n, _"'h" ...... _. __

P1\.1on Assembly __ ._._._.

1"""1'$:

_.It .. _ -:5

....... 24

'" _ ___ .36

. ... . __ -30 __ ... 13

_ .. _17

.. ........ 2 ,1$. 16.17

__ . __ 16

Coolant C ircuUlllIJ ,._ ... _ ..... _. __ .•.• _.h • ..JO Fuell.,ft ...... _ .. ........ h • H .... _ .... __ ... . ..... ....... ___ .. 2S lnJKlion .... ...................... _ ........ _ ....... _ .. ...... _ •. _25 Raw Walcr (OvahauJ) , ....... _______ .............. _ ....... 31

PIIsh Rod ... _ ......... _ ... ____ .. ._ .. _._. __ 15 Ra .... W:atcr Pump Owmaul _._ _ •• _ .. __ ...3 I

Rear 0i15eJJ .... ......... . .. __ ..... _._ __"

Sclo",umn: 5.0KW BCD SUI'~ Ph&se ............. _. __ ........... .14

7.6KW BTD SinJIe Pmse ..... __ .... _ ................. _~ ! BT ( 12 stud) ......... _ ...... _ .. _. ___ ....... _.. ... .._ .. ,46

GencntOf Wllh OC Ban..,. Chargll'll C ,rcull _ ..35 S<;re",s - Suno;brds ___ 68

Seabms ........ _. . .. _ ...... __ . _ , ... 68 ~nder _ 0.1 ~""" .••.•••• H ••• _ _ _ _ ............... _.36 ~NI Number l.oClhon ........ ................ _ ..... _ ... __ .1 Shon: Power T r.msfI:T SWII,h .......• _ •• __ __ , .......... .53. 51 Spcclt'ic<J1ions - EnJ,ne ... ___ ..... _ .. _ ... _ .... SI. 63 Specc"iC:,,1I0fU -~on _ .... __ .. _ .. M ... _Sl. 63 Speed AdjUSlJ'nm1 _ ...... _. __ ... _. __ .21 SpIll Tim'n&-. __ ... _ .. _ ••.. ......... _._._._._ .•• _ ..26 S,ane' Motor ........ .... M~ ......... _ ......... . . ............. __ .J2 Switch - 0.1 Pres..u~ .... .................. _._ ...... .......... l6 T~t . impection ...... ........... _ .......... _ ...•. ___ .1 ~

TnunJ for 0vertw.1 ............. _ ... __ ...... ~_. ._ ... _ .. _1

Thmnoiw Auembly _."_.__ " TimlnJ Gar Use __ "'H"' ___ "' ____ .... 13

lim'lIi Co'·e • . _ .. ___ .. __ .. .. ................. _ ...... 13

lim,nJ G¢ar InspcctlOf1 .............. _ ...... _._ ................ I-:

T,mtI'lJ Gear InSl-lliltoon ,........ ___ ............ H. I ~

TiminJ Gear RCmDvaJ .... _ ....... _ .... _...... • .... _ _ !.:

INDEX ToI~,...ltcn .. 1UI UmilJ: ___ .. . C.1m$~t ._._. ___ ._._ ..... . __ .... 66 Conn«ung RodIC<KI~ttn~ Rod IkJnn~ .......... 66 Cr:mkw f':md M~," 8c~mIJl ........... _ ..... __ ._66 C)'I"~r Block. Piilon and PIston PIn ._ .... _ . . _. __ 65 Cylirwkr Hc3d:md Valvc Spnng. __ __________________ __ __ _ 65

Rocker Arm:mel Roc~er Shaft _ ...... _ ........... _ .. 65 Slant r Motor . '-._ .. _ _ ...... _ __ ._._.~ ..... __ _ . __ 66

Toppct .............. _ ... _. __ .................. ............ _ .. _.66 Timing c",ar ____ ..... _ ... _ ......... __ .. __ . __ .... _ .. _65

Vah-c Guide. Vah'C ;mel Vah'. Spnng ............. .... 65 V31,·c Timlng . ____ .............. _ .. _ .... _ ..... __ ... _ ............. _65

Torqu<c Sprtng SeL. .. _., ............... _ ...... _ ..... _ .... _ ..... 20 Tools-Gcner.uor [)1!_tS51:mbl~ __ __ ... __ ..... __ _____ __ __ ____ . __ 6--1

T.".q"~J:

SWIIbrd Hard",,,", ....... .. .. ............ ....... .. ...... ... , ... 68 Wesrcrbeke ComponentS ._ .............. _ ..... _ ..... _ .... 67

71

r,,,@wIrOOlu.g: . _ .39 AIICrn>!Of ••....•.

BC Gencr.ltor __ __ ...... _ .... __ ... _ ............... S6 BT Gener.1lor ....... ........... _...... . .... .-17 Eng"" _ ................... , ... , .. " , .. ,. . . .3

V31~e Camsh;lft RCmo"31 ___ ____ _ 14

V:tl, .• CIeu.lsK. _ ... _ .... ..... _ ......... _ .................... I 2. 38 Val". GUlt!c ~pl:K.ment _ .... _._ ... _ .... _.. _10

Valv.lnsp.nion .. .-_ .•.. .. _. __ ........ _ ....... ...... _._ ...... II ":!Iv. lnitaIlauon ....... _ .. _ .... _ .. .. _ ...... _ .... .. ..... ______ .. 11

Val". Rcmo>, .L .. ____ . __ ........... .............. ....... . .. ...•. 11 Vah·. Seal R ....... r .. , ......... _......................... . .. _1 0

V:!Ive Spring ....... __ __ __ ____ ___ ______ __ -. ........... _ .... __ .... , . ..... 11

" lriltg Diagrams I Sch~m<Uia: 7.6 KW ___ ...... __ ___ ... ___ . ____ ._. __ ____ ~_ -I1.·n

5.0 Kw .... ..... , ... _ ..... _ .................... .......... ..... ... -13.44

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